WO2015175587A1

WO2015175587A1 - Improved side curtain airbag

Info

Publication number: WO2015175587A1
Application number: PCT/US2015/030453
Authority: WO
Inventors: Chang Ju; Seung-Ho Choi
Original assignee: Key Safety Systems Inc.
Priority date: 2014-05-13
Filing date: 2015-05-13
Publication date: 2015-11-19
Also published as: KR20170007291A

Abstract

A curtain airbag (2) for mounting along a roof rail (22) of a vehicle has an inflatable cushion (2) and a deflector (10). The inflatable cushion or airbag (2) has inflatable portions (4). The airbag (2) when mounted to and extends along the roof rail (22) of a vehicle and having a mid-portion mountable above a pillar (32). The deflector (10) is sewn on, into or otherwise integral to the inflatable cushion (2) and positioned at the mid-portion. The inflatable cushion (2) when folded or rolled and attached to the vehicle has the deflector positioned directly above the pillar (32) and trim (32a). A deflector (10) can be positioned above a B, C, D or other pillar.

Description

IMPROVED SIDE CURTAIN AIRBAG

Background and Summary of the Invention

[001] The present invention relates to side curtain airbags generally and more specifically to those airbags that are mounted along a roof rail of a vehicle.

[002] Reference is briefly made to figure 1, which illustrates a prior art curtain air bag module 20 installed along the roof rail 22 of a passenger compartment 23 of a vehicle 24. In typical curtain air bag installations the air bag extends from the A-pillar 30 across the B-pillar 32 to the C-pillar 34 (and other pillars) of the vehicle. Generally, the curtain air bag module 20 comprises a rectangular or oblong air bag 40 folded or rolled into a cylindrical

configuration. The folded or rolled airbag is often fixed in this position prior to installation in the vehicle.

[003] The air bag is inflated by an inflator 44. As is known in the art the airbag and/or inflator are modified to accommodate this cooperation. The inflator is appropriately fastened, using one or more fasteners or brackets 46, to the appropriate vehicle structure. As illustrated in figure 1 , the inflator is mounted in the C-pillar; however, the inflator 44 can be mounted proximate any other pillar. Further, as known in the art, the lower corners of the air bag are often secured to adjacent corresponding pillars by a strap or wire or spring 48, which is often called a tether. One forward strap 48 is shown in figure 1 in its stored configuration along the A-pillar. The various components shown in figure 1 are covered by one or more trim pieces hiding them in normal use. The module may also include a deflector or ramp 50 located proximate the B-pillar, which urges the air bag as it inflates to move away from exposed edges of the B-pillar.

[004] US 7,401,805 disclosed an improved deflector or ramp that was not fixedly fastened to the vehicle, B-pillar or to the B-pillar trim. The improved ramp was used in conjunction with and formed a part of a curtain air bag module. Air bags will often include a plurality of mounting features such as tabs, which extend from a selvage region, non-inflatable portion of the airbag.

[005] It is an object of the present invention to provide an improved curtain air bag module.

[006] The present invention provides a greatly simplified deflector that is made part of the airbag cushion thus avoiding the cost and handling of additional components.

[007] These and other objectives are achieved by the invention described hereinafter. [008] The present invention relates to a curtain airbag having an inflatable cushion and a deflector. The inflatable cushion has one or more inflatable portions. The deflector is sewn onto, into or otherwise integral to the airbag and initially located above portions of a selected pillar such as the A, B, C and/or D pillar. Thereafter, the airbag with the deflector is folded or rolled and attached to the vehicle. Upon inflation the deflector covers an exposed edge of the associated pillar.

[009] In one embodiment, the curtain airbag of the present invention has a plurality of mounting features such as tabs which extend from a selvage region or are formed as openings in the selvage region for affixing the airbag to the vehicle. The deflector and rolled, folded airbag cushion, or that portion of the folded airbag cushion proximate the pillar to which the airbag is mounted, are encircled by a frangible tape adapted to release on inflation of the airbag cushion wherein upon airbag deployment, the gas flow channel inflates and bulges outwardly moving the deflector over a top end of the associated pillar. The tabs maintain the deflector near the adjacent pillar. The tabs can also extend from the top seam of the airbag.

[0010] The illustrated curtain airbag has a gas flow channel extending at least partially along the length of a top portion of the cushion and the deflector is sewn or attached parallel to and near the gas flow channel. The airbag cushion when folded or rolled for mounting has the deflector adjacent the gas flow channel. The deflector is oriented and held vertically during mounting and stowage and spaced from the roof rail by the rolled or folded airbag cushion and faces the interior of the passenger compartment. The deflector can be made of a variety of materials including: woven fabric, reinforced fabric, metal, a plastic sewn on or into or attached to the airbag cushion at a non-inflatable portion. The deflector forms a part of the mounted airbag cushion not separately part of or directly attached to the vehicle or roof rail of the vehicle. As mentioned, the deflector upon deployment of the airbag forms a guide covering a top end of the chosen pillar such as the B pillar to prevent the deploying airbag from catching on that pillar or upon the trim that covers the pillar. Preferably, the deflector has a width greater than the width of an exposed edge of the B pillar or trim. A deflector having a width of at least 6 inches (15.24 cm) has been shown to be effective. The vertical dimension or height of the deflector can be about 1.0 inch (2.54 cm) or greater. Brief Description of the Drawings

[0011] The invention will be described by way of example and with reference to the accompanying drawings in which:

Figure 1 is a prior art curtain airbag.

Figure 2 is a plan view of a curtain airbag usable with the present invention.

Figure 2a shows the air bag of figure 2 with two deployment assemblies secured to the airbag such as by sewing.

Figure 2b shows the curtain airbag of figure 2a installed within an exemplary vehicle.

Figure 2c diagrammatically shows the curtain airbag formed into a compact rolled or folded configuration.

Figure 2d shows a variation of the airbag of figure 2a with hanger tabs sufficiently spaced apart to be away from the flap or cover forming part of the deployment assembly.

Figure 3 is a plan view of a preferred deflector assembly and cover according to the present invention.

Figure 3a shows another embodiment of the invention.

Figure 3b is a plan view of a preferred deflector and variations according to the present invention.

Figure 3c shows a modified deflector assembly.

Figure 3d shows the deflector assembly attached to an upper portion of the airbag of figure 2.

Figure 4 is a cross-sectional view showing the airbag of the present invention with a flap and deflector wrapped thereabout.

Figure 5 is an orthogonal view of the curtain airbag of the present invention in a mounted stowed condition on a vehicle in a location above a pillar.

Figure 6 is a cross-sectional view through the center of the deflector of Figure 5 prior to inflation of the airbag.

Figure 6A is similar to Figure 6 showing the airbag cushion and pillar after the vehicle pillar has pushed inward relative to its normal position.

Figure 7 shows the airbag of Figure 6 after it inflates.

Figure 7A shows the airbag of Figure 6A after it inflates.

Figure 7A-1 is an enlarged view of Figure 7 A.

Figure 8 shows a variation of a deflector assembly. Figure 8A shows the deflector assembly of Figure 8 sewn to a portion of an airbag. Figure 9 is another view of an airbag mounted proximate the roof rail.

Detailed Description of the Invention

[0012] Figure 2 shows a curtain airbag 2 having an inflatable portion 4 surrounded by a seam, selvage region or boundary 3 which is not inflatable. As is known in the art, the airbag can include multiple inflatable regions 4. The airbag is shown in a plan view; conceptually this view is representative of an uninflated airbag laid flat upon a table prior to its folding. Figure 2b diagrammatically illustrates some of the vehicle pillars 15 A, 15C as well as the roof rail 15B so that the airbag can be visualized in its operational environment. When mounted within the passenger compartment of the vehicle the illustrated airbag extends between, for example, the A pillar 15A across the B pillar 32 to the rear C pillar 15C. The airbag is connected to the A pillar via a tether 15 that is anchored via anchor 15D to the A pillar. In figure 2b airbag 2 is shown connected to the roof rail via a plurality of mounting features such as tabs 14. Two of these tabs are designated as 14L and as will be seen are positioned in close proximity to a deflator assembly. As needed the air bag can be connected to the C (or other rearward positioned) pillar using another tether or other known mechanism. In figure 2 the tabs 14 and 14L are shown laid flat on the airbag fabric and pointing down. This is one configuration of airbag tabs.

[0013] Prior to being installed in the vehicle, the curtain airbag cushion 2 is rolled or folded into an elongated configuration with its mounting features, i.e. tabs Hand 14L, oriented vertically as shown in figure 2b so the airbag can be placed up against and the tabs secured to the roof rail 15B and other pillars. Each tab has a hole or opening 17 to accept a fastener 46, of known construction, to secure the airbag 2 directly to the vehicle. Tn many instances only one deflector assembly 12 will be used in conjunction with the airbag; in figure 2d two deflector assemblies 12 are shown mounted to the airbag in the position they would achieve as they are so attached. A first deflector assembly is located by the B-pillar 32 and B-pillar trim 32a and a second deflector assembly shown by the C pillar and its trim to show the flexibility of the invention.

[0014] The deflector assembly 12 is shown in greater detail in figure 3 and holds a deflector 10 shown in figure 3a in a preferred orientation as the airbag inflates relative to the top of an associated pillar. The deflector assembly 12 includes a flap 1 1 which holds the deflector 10. The flap 11 is sewn to the airbag 2 in its selvage region 3 near the top of the airbag as also shown in figures 3d, 2d and others, generally between two mounting tabs 14L. Numeral 1 lb is representative of the sewn seam. In the embodiment shown in figure 3, the flap 1 1 includes a slot or pocket 1 1 a into which a rectangular shaped deflector 1 0 is slid. The deflector 10 in figure 3a is rectangular and can be made as a rigid, semi-rigid or even flexible member and sufficiently wide to cover an exposed portion of the top of the B-pillar upon deployment. If the deflector 10 is placed into the pocket 1 la the pocket 1 1a can be sewn closed securing the deflector 10 therein. Alternately, the deflector after being inserted into the pocket can be secured to the flap material in any known manner. Reference is again made to figure 3a. As mentioned a rectangular shaped deflector 10 is shown in solid line. Figure 3a also shows the shape of the deflector 10 may approach a square shape or even triangular shape (both shapes shown in phantom line). Other shapes are within the purview of the present invention. The cover pocket 1 la is not a requirement of the invention as the deflector

10 can be secured directly to the cover 1 1 using any appropriate technique such as welding, sewing, riveting, etc. In figure 3b two flexible deflectors 10 perhaps using seat belt or similar material are sewn to the flap 1 1 . The sew seam is designated by numeral 1 lb.

[0015] For each of the various airbags shown after they are rolled or folded and mounted, the deflectors 10 are positioned in proximity to the top end of the associated pillar and/or trim, such as the B pillar or another pillar. This construction permits the deflector 10 to be placed over the top end of the pillar as the air bag inflates preventing the airbag 2 from snagging on the top or open end of the pillar or pillar trim on airbag deployment.

[0016] The sequence of construction of the present invention may follow the following steps. An airbag 2 such as illustrated in figures 2 or 2d is constructed. The deflector assembly 12 is constructed according to figures 3 - 3c and secured such as by sewing at scam 1 lb to the airbag at a location that will be over the associated pillar and trim such as above the B pillar (and trim). Tn figures 3d, and 2b the width of the deflector assembly more closely

approximates the spacing between the extreme sides of the hanger tabs 14L while in figure 2d the spacing between the hanger tabs 14L is greater than the width of the deflector assembly 12.

[0017] The airbag 2, with the deflector assembly or assemblies 12 in place as shown in figures 2a and 2d, is folded or rolled. The rolling or folding starts from the bottom to the top, and when complete forms a compact, sausage-like compact configuration 60 which is well known and also shown in figure 2c. The deflector assembly 12 which is secured to the top of the airbag 2 is bent over the top edge of the airbag as shown in figure 4 which places the flap

1 1 behind the compactly configured airbag 60. Then the flap 1 1 is moved such as being rolled or folded under the folded or rolled, compactly configured airbag 60 to form a partial loop about this local portion of the rolled or folded airbag. In the preferred embodiment of the invention the end of the looped deflector assembly is left loose as shown in figure 4. As shown in figures 5, 6 and others a length of sticky tape 7 is used to keep the deflector assembly 12 in a rolled-up orientation against the rolled-up airbag 60. Also shown in figure 4, the rolled airbag 60 has been rolled using a roll technique that places the lower, rolled-up portions of the airbag facing the exterior (including the windows) 62 of the passenger compartment.

[0018] Figure 2a-d show a variety of known mounting features used to mount an airbag to the roof rail of a vehicle. Airbag 2 uses a plurality of tabs 14 sewn to the top selvage region 3 facing downward. To achieve the condition in figure 2c all tabs 14 and 14L are folded or rotated upward following arrow 64 so the tabs now extend vertically upward. One such tab 14 has been so moved and is shown in phantom line in its upward orientation. Alternately, the tabs 14 could have been initially formed or sewn to the top part of the airbag in an upward, vertically extending configuration as shown by tab 14M. Those familiar with airbag construction will recognize both types of tabs are generally equivalent. Further, the airbag mounting features need not include tabs but can be formed by holes 17a formed in the selvage region 3. Regardless of the tab or mounting feature used a mounting fastener 46 is used to fasten the tab and in general the airbag to the vehicle, for example, along the roof rail. Any number of differently shaped and functioning mounting fasteners can be used. The mounting fastener 46 in figure 4 is offered by way of illustration.

[0019] The fastener openings 17 and the hanger tabs 14L are provided to locate the deflector 10 relative to an associated pillar and to assist mounting the airbag to the roof rail of the vehicle at this location. The deflector 10 provides a sufficient level of rigidity preventing the airbag from deflecting or bending between these two tab locations so as to prevent the airbag, as it inflates, from being trapped within a void that might be formed at the top of the pillar or its trim as it unfolds and to isolate the inflating airbag from any rough edges on the associated top end of the pillar or trim so that the airbag is not caught or ripped by such edges. In practice it would be obvious to say the deflector should be sized appropriately. The deflector 10 if used in association with a B pillar will be as wide, if not wider, than the B pillar (and trim) typically in the range of 23.8 - 25.4 cm. The height h needs to be of sufficient dimension so the deflector will lie upon the top edge of the pillar and/or trim in all operative conditions. [0020] The phantom lines associated with the deflector 10 of figure 4 show the height h of the deflector can be varied to insure its function of resting upon the top of the pillar can be performed. For example, and as discussed below, in certain side impact accidents the side pillar can be pushed inward moving the top edge of the pillar further into the passenger compartment. The deflector 10 can be sized to accommodate this unusual happening.

[0021] In figure 5 the airbag is shown in a stowed position directly over B pillar 32 and trim 32a as attached to a side or roof rail 22 of the vehicle. The headliner 80 shown in figure 4 protects the curtain air bag 2, inflator and related structure. Also the B-pillar trim 32a is shown in figure 5 and diagrammatically in figure 4 covers the B-pillar. Upon deployment of the airbag, the releasable tape 7 holding the airbag 2 in its rolled condition of figure 4 is broken, whereupon the deflector 10, which is in cover 1 1 , is moved from its initial position shown in figure 4, which in general is a vertical orientation to a more horizontal position or beyond horizontal position such that it can lie directly on top of an associated pillar end 22A. The size of the tape or cover 1 1 and the location of the deflector on the tape covers let the deflector be positioned operatively upon the top of the pillar.

[0022] As the airbag 2 continues to unfold and unroll, it will pass directly over this reinforced stiffening member or deflector 10 which as mentioned shields the deploying airbag 2 from negatively interacting with the exposed surfaces pillar 32 and or trim 32a. Also as previously mentioned, the deflector assembly is not limited for use with the B pillar, as shown above a second deployment assembly 12 with a second reinforcement member or deflector 10 can be mounted between another set of hanger tabs 14L located at another part of the airbag such as at the aft or rear end or at the front by the A pillar. As can be appreciated additional deflector sl O can be used with particularly long vehicles having D, E and F pillars and associated trim.

[0023] Figures 6 and 7 show the inflated and deployed airbag 2. Figure 6 is a cross-sectional view through the center of the deflector of Figure 5. Figure 6 shows the pre-inflation position of deflector 10 in phantom line as well as the position of the deflector 10 moments after the initiation of inflation with the tape 7 broken and the deflector 10 positioned above the top of the B pillar and B-pillar trim 32a. Figure 7 shows the airbag of figure 6 after it inflates. The height, h, of the deflector 10 as shown in figure 3b should be large enough to permit the deflector 10 to also be positionable above the top of the B pillar trim and B pillar in case of certain severe side impact accidents. This condition is illustrated in figures 6A, 7A and 7A- 1. Figure 6A is a cross-sectional view and shows the side of the vehicle has already been pushed inward, more particularly the B pillar and trim are now inboard relative to that shown in figure 6. Figure 6A shows the pre-inflation position of deflector 10 in phantom line as well as the position of the deflector 10 moments after the initiation of inflation with the tape 7 broken and the deflector 10 positioned above the top of the B pillar and B-pillar trim. Figure 7 A shows the airbag of figure 6 after it inflates and figure 7A-1 shows the entire airbag 2 in cross-section.

[0024] In the above views, the inflated chamber 4 is shown providing an inflated volume for protecting a seated occupant from the side of the vehicle by the airbag 2. The deflector 10, when opened, is pushed by an adjacent portion 9 of the air bag (see figure 4) that is initially filled. As the airbag fills the deflector 10 is moved from its initial vertical position to a horizontal or slightly past horizontal position directly above the open end of a pillar 32 or trim 32a. When this occurs, the remaining portion of the airbag 2 unfurls as it unrolls or unfolds during deployment passing directly over the deflector 10 which acts as a protective covering, shielding the air bag from snagging or catching on any sharp obstructions on the open end of the pillar 32. As can be seen, the entire deflector assembly 12 is made integral to the cushion material by being secured directly onto the cushion fabric. The deflector 1 0 and the entire airbag 2 can be provided as a single assembly such that it can be easily mounted into the vehicle with no additional or separate components being required other than fasteners. This is a great advantage over the prior art wherein separate components or ramps are provided separate from the airbag cushion or even in those where the airbag tab was used as a means to loosely tether a deflector. These loose components provide problems during assembly and can cause noise and other unpleasant attributes that affect the normal operation of the vehicle. The present invention, by securing the deflector 10 inside the flexible cover 1 1 , ensures no additional noise or sound generating effects can occur.

[0025] Reference is briefly made to figure 8 which shows an alternate deflector assembly 12a identical to deflector assembly 12 with the exception of the addition of two tabs 14N. In figure 8a deployment assembly 12a is shown sewn to the airbag along seam 70 as was deployment cover 12. The initial steps of assembling of the airbag to the vehicle with deployment covers is the same as described above. As previously described, the deflector assembly 12 is rolled under the compactly rolled airbag 60 and an edge of the flap 1 1 is left unattached. In this embodiment, after the deflector assembly 12a is rolled under the compact airbag 60, a first set of tabs comprising one tab 14L and one tab 14N are placed together so that openings 17 are aligned to enable a fastener 46 to be positioned through both openings. Then this step is repeated with another set of tabs comprising the other tab 14L and the other tab 14N. As can be appreciated, by joining the two sets of tabs 14L and 14N together the deflector assembly 12a is kept in a looped and secured configuration about the compact airbag 60. The sticky tape 7 can be used or eliminated. This relationship is shown in figure 9 and in phantom line in figure 4.

[0026] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.

Claims

CLAIMS What is claimed is:

1. A curtain airbag for a vehicle, the curtain airbag comprising:

an inflatable cushion having at least one inflatable portion, the cushion is mountable along a roof rail of the vehicle and having a mid-portion which spans a pillar of the vehicle; a deflector sewn or otherwise affixed to the inflatable cushion and positioned at the mid-portion above the pillar; and

wherein the inflatable cushion when folded or rolled and attached to the vehicle has the deflector above the pillar.

2. The curtain airbag of claim 1 further comprises: a plurality of mounting tabs for affixing the airbag to the vehicle.

3. The curtain airbag of claim 1 wherein the curtain airbag has a top seam or selvage portion which is secured directly to the vehicle or secured via mounting tabs.

4. The curtain airbag of claim 2 wherein the deflector is spaced between a pair of mounting tabs below vehicle attachment locations at or near the top seam or selvage portion.

5. The curtain airbag of claim 1 wherein the curtain airbag has a longitudinal gas flow channel extending at least partially along the length of a top portion of the cushion and the deflector is sewn or attached parallel to and near the gas flow channel.

6. The curtain airbag of claim 5 wherein the airbag cushion when folded or rolled for mounting has the deflector adjacent the gas flow channel and facing toward an interior of the vehicle above a B pillar.

7. The curtain airbag of claim 6 wherein the deflector is oriented and held vertically during mounting and stowage and spaced from the roof rail by the rolled or folded airbag cushion.

8. The curtain airbag of claim 7 wherein the deflector and rolled or folded airbag cushion arc encircled by a frangible tape or a tab or tabs with a tear seam or breakaway feature adapted to release on inflation of the airbag cushion.

9. The curtain airbag of claim 7 wherein upon airbag deployment the gas flow channel inflates and bulges outwardly moving the deflector horizontally over a top end of the B pillar.

10. The curtain airbag of claim 1 wherein the deflector is a material made of woven fabric, reinforced fabric or a plastic material sewn on or into or attached to the airbag cushion at a non-inflatable portion.

11. The curtain airbag of claim 10 wherein the deflector is a stiff material sewn in a pocket or fabric cover on the non-inflatable portion of the airbag cushion.

12. The curtain airbag of claim 1 wherein the deflector forms a part of the mounted airbag cushion not separately part of or directly attached to the vehicle or roof rail of the vehicle.

13. The curtain airbag of claim 12 wherein the deflector forms a guide over a top end of the B pillar to prevent the airbag from catching on the B pillar.

14. The curtain airbag of claim 11 wherein the airbag cushion is made of a flexible fabric material and the deflector is held in the pocket sewn onto the cushion fabric.

15. The curtain airbag of claim 1 wherein the deflector has a length greater than the top of the B pillar.

16. The curtain airbag of claim 15 wherein the length is at least 6 inches (15.24 cm).

17. The curtain airbag of claim 11 wherein the deflector has a width of about 1.0 inch (2.54 cm) or greater.

18. The curtain airbag of claim 1 wherein the deflector is a stiff material affixed or sewn directly onto the exterior of the cushion fabric.

19. The curtain airbag of claim 1 wherein the stiff material is a woven material.

20. The curtain airbag of claim 1 further comprises one or more deflectors positioned above a C or D pillar.