Extruded Manifold With Plastic Housing

The present invention relates to a vehicle airbag assembly, and more particularly to an airbag module including a manifold and an airbag deployment housing.

Vehicle airbags have become very popular within the automotive industry, and have even become standard equipment in many vehicles. Airbag modules have been developed which are complete assemblies in that they contain an inflator, a container for the inflator, an airbag and a deployment housing attached to the container which houses the folded airbag. This module is typically attached to support structure beneath the instrument panel or steering wheel.

In present designs, airbag module assemblies come in a variety of configurations, and include a variety of components. However, known designs include a large number of parts and require substantial time and effort for assembly.

One such airbag module is disclosed in U.S. Pat. No. 5,263,739. The '739 patent provides a plastic housing in combination with an extruded inflator holding member. The inflator holding member includes slots for slidably receiving an airbag pack assembly. The airbag pack assembly includes an airbag, a U-shaped retainer, and an airbag deployment housing. For assembly, the airbag must first be inserted into the airbag deployment housing, and the hems of the airbag must be lined up with the slots formed at the bottom of the airbag deployment housing. The U-shaped retainer is then slid laterally into the hems of the airbag and into the slots of the airbag deployment housing to complete the bag pack assembly. Finally, the bag pack assembly is slid laterally into the grooves of the extruded inflator holding member and end plates are added in order to complete the assembly. The various steps of this process may be awkward and time consuming due to the number of components and the difficulty in mating the hem loops with the grooves in the airbag deployment housing, sliding the retainer into the airbag hem loops, and sliding the bag pack assembly into the grooves on the inflator holding member.

Another airbag module is shown in U.S. Pat. No. 5,332,356. Again, this design requires first inserting retainer rods into the airbag hems, and then sliding the airbag assembly laterally into slots formed in the manifold. Assembly also requires installation of bolts and end caps to hold the assembly together. Further, the manifold is a two-piece design, which adds assembly time.

Other complex airbag module assemblies, such as that disclosed in U.S. Pat. No. 5,407,227, include a large number of components and require lateral sliding of the airbag and deployment housing onto the manifold.

It is desirable to provide an airbag module of a simplified design with a one-piece manifold which does not require the airbag pack assembly to be slid laterally into a position of engagement with the manifold, thereby reducing assembly time.

The present invention solves the above referenced problems experienced in prior art assemblies by providing an airbag module assembly which includes a one-piece manifold and an airbag deployment housing which is pressed into engagement with the manifold without the need for bolts or lateral sliding of the bag pack assembly. The deployment housing is snapped, staked or crimped into engagement with the housing.

The present invention provides a vehicle airbag assembly, comprising a generally hollow manifold having at least one gas discharge opening formed therethrough and having a pair of ears extending therefrom. An airbag deployment housing includes a central aperture formed therethrough in fluid communication with the gas discharge opening. The airbag deployment housing further includes a plurality of tabs extending therefrom adjacent the central aperture for mating engagement with the ears. An airbag is provided with a first portion forming an airbag opening, and includes a plurality of apertures formed through the first portion adjacent the opening for respective engagement with the plurality of tabs to secure the airbag to the deployment housing. This arrangement facilitates respective engagement of the tabs within the plurality of apertures prior to connection of the chute with the ears.

The present invention further provides a vehicle airbag assembly, comprising an airbag having a first portion forming an airbag opening and having a plurality of apertures formed through the first portion adjacent the opening. A hollow airbag deployment housing is provided for housing the airbag. The airbag deployment housing has a plurality of tabs for respective cooperation with the apertures formed through the first portion of the airbag to secure the airbag to the deployment housing. A one-piece generally hollow manifold is provided, having at least one opening formed therethrough in fluid communication with the central aperture of the deployment housing. The manifold includes a pair of ears extending therefrom to facilitate mating cooperation with the plurality of tabs to secure the deployment housing and airbag to the manifold.

Accordingly, an object of the present invention is to provide an airbag module assembly which is simple in design and requires significantly reduced assembly time.

A further object of the present invention is to provide an airbag deployment housing which is snapped, staked, swaged or crimped onto the manifold, and does not require bolts or end caps for assembly.

Yet another object of the present invention is to provide an airbag module assembly which does not require longitudinal sliding of the bag pack assembly into slots on the manifold.

The above objects and other objects, features and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.

FIG. 1 shows a partially cutaway exploded perspective view of an airbag module assembly in accordance with the present invention;

FIG. 2 shows an exploded perspective view of a manifold and airbag deployment housing in accordance with the present invention;

FIG. 3 shows an end view of a manifold and airbag deployment housing taken from FIG. 2;

FIG. 4 shows a side view of a manifold and airbag deployment housing taken from FIG. 2;

FIG. 5 shows a partially cutaway vertical cross-section through a partially assembled airbag module in accordance with the present invention; and

FIG. 6 shows a partial vertical cross-section of a manifold and airbag deployment housing in accordance with the present invention.

FIG. 1 shows an airbag module assembly 10 in accordance with the present invention. The airbag module assembly 10 includes an airbag 12, a plastic airbag deployment housing 14, an aluminum manifold 16, and an inflator 18.

The airbag 12 includes a first portion 20 forming an airbag opening 22. The first portion includes apertures 24,26,28 formed therethrough adjacent the opening 22 for respective engagement with the tabs 30,32,34 extending from the airbag deployment housing 14. An opposing set of apertures (not visible) are formed through the first portion 20 opposite the apertures 24,26,28 on the other side of the opening 22.

The airbag deployment housing 14 includes a central aperture 36 formed therethrough. The tabs 30,32,34 extend from the airbag deployment housing 14 adjacent the central aperture 36. The airbag deployment housing 14 further includes end tabs 37,38,39,40 extending therefrom. The airbag deployment housing 14 also includes side walls 42,44,46,48 for housing the airbag 12, and for guiding deployment of the airbag 12, and further including an opposing second set of tabs (not visible in FIG. 1) across from the tabs 30,32,34.

For assembly, the airbag 12 is inserted through the deployment housing 14, and the two sets of apertures 24,26,28 of the airbag are mated with the two sets of tabs 30,32,34 to secure the airbag to the deployment housing. Thereafter the air bag is folded within the deployment housing 14. Depending upon the specific application a cover, having a frangible tear seam may be attached to the deployment housing 14. Typical of deployment housing covers the cover would also include hinge portions which permit parts of the cover on either side of the tear seam to pivot outwardly as the air bag is inflated.

The assembled airbag 12 and deployment housing 14 are moved radially to the manifold and positioned in cooperation with the ears 50,52 of the manifold 16. Each ear 50,52 forms a channel 54,56 for receiving the tabs 37,38,30,32,34,39,40 of the airbag deployment housing 14. The tabs 37,38,30,32,34,39,40 are snapped into position between the resilient ears 50,52 in order to secure the airbag deployment housing 14 to the manifold 16. As the tabs are pressed between the ears 50,52, the ears flex outwardly to allow the tabs to pass between the ears. Once the tabs have cleared the ears, the ears resiliently snap into position to secure the tabs in the respective channel 54,56.

The manifold 16 includes a plurality of gas discharge openings 58, which are placed in fluid communication with the central aperture 36 of the deployment housing when the module is assembled. Finally, the inflator 18 is inserted into the manifold 16, and the manifold is crimped about the inflator providing a fluid seal therebetween, thus completing the assembly.

As shown in FIG. 3, the ears 50,52 include swaged portions 60,62 at opposing ends of each ear in order to prevent longitudinal (axial) sliding movement of the airbag deployment housing 14 along the ears 50,52. The end tabs 38,40 are positioned to engage against the swaged portions 60,62 if the airbag deployment housing 14 moves longitudinally along the manifold 16.

As shown in FIGS. 2, 3 and 6, the deployment housing 14 includes central curved portions 64,65 between the respective end tabs. The central curved portions 64,65 of the housing engage the first and second chamfered ends 66,68 of the manifold 16 in order to further prevent sliding lateral movement of the airbag deployment housing 14 with respect to the inflator 16. Accordingly, the end tabs 37,38,39,40 are pinched between the swaged portions 60,62 of the ears 50,52 and the chamfered ends 66,68 of the manifold in order to prevent sliding lateral movement of the airbag deployment housing 14 along the manifold 16.

FIG. 5 more clearly shows the final airbag module assembly in cross-section. The first portion 20 of the airbag 12 is pinched between the tab 34 and the ears 50,52, with each tab 30,32,34 extending through a corresponding aperture of the airbag. As shown, tab 34 extends through aperture 28. Ignition of the inflator 18 will send pressurized gas through the gas discharge openings 58, through the airbag deployment housing 14, and into the airbag to fill the airbag.

In this manner, the airbag apertures 24,26,28 are engaged with the tabs 30,32,34 to secure the airbag 12 to the airbag deployment housing 14, and the assembly is completed by merely engaging the airbag deployment housing 14 between the ears 50,52 of the manifold 16. This design substantially reduces assembly time in comparison to present airbag module assemblies.

The inflator 18 and manifold 16 have chamfered first and second longitudinal ends which cooperate to secure the inflator within the manifold while allowing insertion of the inflator into the manifold. The first end 70 of the inflator has a smaller diameter than the first end 72 of the manifold 16 in order to allow insertion of the inflator 18 into the manifold 16. The second end 74 of the manifold has a diameter sufficiently small to prevent the inflator 18 from exiting the manifold. Similarly, the second end 76 of the inflator comprises a diameter of sufficient width to allow insertion thereof through the first end 72 of the manifold and to prevent removal of the second end 76 of the inflator from the first end 72 of the manifold. Accordingly, the inflator 18 is nearly press fit within the manifold 16 by means of the smaller diameters of the first and second ends 72,74 of the manifold, which result from the chamfering 66,68 of the manifold 16. Therefore, no end plates are required. Alternatively, the manifold 16 may be crimped about the inflator 18 to provide a fluid seal.

The inflator 18 further includes an electrical attachment plug 78 for electrical communication with the inflator.

In alternative embodiments, the ears 50,52 of the manifold are spaced sufficiently apart to let the tabs of the housing be placed between the ears 50,52 without engaging the ears. The ears are then crimped together about the tabs, or staked, such as to permanently deform the ears inwardly, or swaged to secure the housing in position with respect to the manifold.

While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize alternative designs and embodiments for practicing the invention. Thus, the above described preferred embodiment is intended to be illustrative of the invention which may be modified within the scope of the following appended claims.