Inflatable curtain housing with deployment flap

[0002] The present invention relates to an inflatable apparatus for helping to protect a vehicle occupant in the event of a side impact to the vehicle and/or a vehicle rollover.

[0003] It is known to inflate an inflatable vehicle occupant protection device to help protect a vehicle occupant in the even t of a vehicle collision. One particular type of inflatable vehicle occupant protection device is an inflatable curtain that inflates away from the roof of the vehicle downward inside the passenger compartment between a vehicle occupant and the side structure of the vehicle in the event of a side impact or rollover. Such known inflatable curtains are typically stored in a housing that opens upon inflation of the inflatable curtain. A known inflatable curtain is inflated from a deflated condition by inflation fluid directed from an inflator to the inflatable curtain.

[0004] The present invention relates to an apparatus for helping to protect an occupant of a vehicle that has a side structure and a roof. The apparatus comprises an inflatable vehicle occupant protection device and a housing for storing the protection device in a stored position. The protection device is inflatable away from the vehicle roof into a position between the side structure of the vehicle and a vehicle occupant.

[0005] The housing comprises an elongated channel portion that helps define a chamber for receiving the protection device. The channel portion has spaced first and second longitudinal edges extending along the length of the channel portion. A closure flap extends from the first longitudinal edge and has an end releasably connected to the second longitudinal edge to at least partially enclose the protection device in the chamber when the protection device is in the stored position.

[0006] The housing also comprises a deployment flap that extends from the channel portion adjacent the second longitudinal edge of the channel portion. The deployment flap overlies the closure flap when the closure flap is connected to the second longitudinal edge. The deployment flap is adapted to move into a position overlying a vehicle side trim piece when the protection device is inflated. The deployment flap directs the protection device to inflate inwardly of the vehicle side trim piece between the occupant and the trim piece.

[0007] The foregoing and other features of the present invention will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, in which:

[0008] FIG. 1 is a schematic view of an apparatus for helping to protect a vehicle occupant illustrating the apparatus in a deflated condition, according to the invention;

[0009] FIG. 2 is a schematic view of the apparatus of FIG. 1 in an inflated condition;

[0010] FIG. 3 is a sectional view of the apparatus taken generally along line 3—3 in FIG. 2;

[0011] FIG. 4 is a sectional view of the apparatus taken generally along line 4—4 in FIG. 1;

[0012] FIG. 5 is a sectional view of the apparatus taken generally along line 5—5 in FIG. 2;

[0013] FIG. 6 is a sectional view of an apparatus for helping to protect a vehicle occupant illustrating the apparatus in a deflated condition, according to a second embodiment of the present invention; and

[0014] FIG. 7 is a sectional view of the apparatus of FIG. 6 in an inflated condition.

[0015] As representative of the present invention, an apparatus 10 helps to protect an occupant of a vehicle 12. As shown in FIGS. 1 and 2, the apparatus 10 includes an inflatable vehicle occupant protection device in the form of an inflatable curtain 14 that is mounted adjacent the side structure 16 of the vehicle 12 and the roof 18 of the vehicle. The side structure 16 of the vehicle 12 includes side windows 20, an A pillar 30, a B pillar 32, and a C pillar 34. An inflator 24 is connected in fluid communication with the inflatable curtain 14 through a fill tube 22. The fill tube 22 may be constructed of any suitable material, such as metal, plastic, or fabric. Also, those skilled in the art will recognize that the fill tube 22 may be omitted, in which case the inflator 24 may be connected directly to the inflatable curtain 14.

[0016] The fill tube 22 has a first end portion 36 for receiving fluid from the inflator 24. The fill tube 22 may be connected directly to the inflator 24 or a manifold (not shown) may connect the fill tube to the inflator. The fill tube 22 has a second end portion 38 disposed in the inflatable curtain 14.

[0017] The inflator 24 contains a stored quantity of pressurized inflation fluid (not shown) in the form of a gas to inflate the inflatable curtain 14. The inflator 24 alternatively could contain a combination of pressurized inflation fluid and ignitable material for heating the inflation fluid, or could be a pyrotechnic inflator that uses the combustion of gas-generating material to generate inflation fluid. As a further alternative, the inflator 24 could be of any suitable type or construction for supplying a medium for inflating the inflatable curtain 14.

[0018] The apparatus 10 includes a housing 26 that stores the inflatable curtain 14 in a deflated condition. The fill tube 22, the deflated inflatable curtain 14, and the housing 26 have an elongated configuration and extend along the vehicle roof 18 and along the side structure 16 of the vehicle 12 above the side windows 20. The fill tube 22, inflatable curtain 14 and housing 26 are connected to the vehicle 12 by known means (not shown), such as brackets.

[0019] As best illustrated in FIG. 3, the inflatable curtain 14 comprises first and second panels 40 and 42 that are arranged in an overlying manner. Preferably, overlapping portions of the first and second panels 40 and 42 are secured together by weaving or stitching the panels together along at least a portion of a perimeter 44 (FIGS. 2 and 3) of the inflatable curtain 14 to form an inflatable volume of the curtain.

[0020] The perimeter 44 is defined at least partially by an upper edge 50 (FIG. 2) of the inflatable curtain 14, an opposite lower edge 52 of the curtain, and front and rear portions 54 and 56, respectively, of the curtain spaced apart horizontally along the upper and lower edges. In the embodiment illustrated in FIG. 2, the front and rear portions 54 and 56 of the inflatable curtain 14 are partially defined by front and rear edges 60 and 62, respectively, that are spaced horizontally apart along the upper and lower edges 50 and 52 and extend vertically between the upper and lower edges. The front and rear edges 60 and 62, however, could be omitted and the upper and lower edges 50 and 52 could be extended until they intersect, in which case the front and rear portions 54 and 56 would be defined by the intersecting upper and lower edges. Also, while the front and rear edges 60 and 62 are illustrated as being generally vertical, they could extend at some other angle between the upper and lower edges 50 and 52.

[0021] As illustrated in FIG. 3, the inflatable curtain 14 is formed from a sheet of material that is folded over to form the overlying first and second panels 40 and 42. It will be recognized by those skilled in the art, however, that the inflatable curtain 14 could have alternative constructions. For example, the first and second panels 40 and 42 could be formed from separate sheets of material arranged in an overlying manner and secured together by stitching, ultrasonic bonding, heat welding, or adhesive bonding that extends around the entire perimeter 44 of the panels to form the inflatable curtain 14. As a further alternative, the inflatable curtain 14 could be woven as a single piece of material.

[0022] The first and second panels 40 and 42 are preferably constructed of a fabric, such as nylon, that may be coated with a gas impermeable material, such as urethane or silicone. The inflatable curtain 14 thus may have a substantially gas-tight construction. Other materials, such as elastomers, plastic films, or combinations thereof, may also be used to construct the inflatable curtain 14. The first and second panels 40 and 42 may also be formed of single or multi-layered sheets of material.

[0023] As illustrated in FIG. 4, a vehicle roof rail 70 is located at the intersection of the side structure 16 of the vehicle and the vehicle roof 18. The side structure 16, roof 18 and roof rail 70 are formed from pieces of sheet metal that are stamped or otherwise formed into predetermined shapes and welded or otherwise connected to form a desired structure. In the embodiment illustrated in FIG. 4, inner and outer pieces of sheet metal 72 and 74, respectively, are used to form the side structure 16, roof 18 and roof rail 70. A third piece of sheet metal 76 helps to form the B pillar 32 of the vehicle 12. Those skilled in the art will recognize, however, that the side structure 16, roof 18, roof rail 70, and B pillar 32 may have alternative constructions.

[0024] The housing 26 is preferably constructed of a single piece of homogeneous material that is extruded or injection molded from a plastic material. The housing 26 includes an elongated channel portion 80 that defines a chamber 82 for receiving the fill tube 22 and the inflatable curtain 14. The channel portion 80 comprises an arc-shaped end portion 84 and an outer wall portion 86 connected to a first end 88 of the arc-shaped end portion by an angled portion 90 of the housing 26. As illustrated in FIG. 4, the end portion 84 may extend more than 180 degrees around the fill tube 22 to help secure the fill tube in the housing 26. A second end 92 of the arc-shaped end portion 82, opposite the first end 88, defines a first longitudinal edge 94 of the channel portion 80. A second longitudinal edge 96 of the channel portion 80 is defined along the end of the outer wall portion 86 opposite the end portion 84.

[0025] A closure flap 100 extends from the first longitunal edge 94 and is interconnected with the outer wall portion 86 along the second longitudinal edge 96 by means, such as interlocking beads 106. The closure flap 100, when connected to the outer wall portion 86, at least partially closes the channel portion 80 and at least partially encloses the fill tube 22 and the inflatable curtain 14 in the chamber 82 in a folded and stored condition.

[0026] The end portion 84, outer wall portion 86, closure flap 100, and the beads 106 may extend substantially along the entire length of the housing 26. This may be the case, for example, if the housing 26 is constructed from extruded plastic. Those skilled in the art, however, will recognize that certain of these elements may not extend along the entire length of the housing 26. For example, the beads 106 may be located intermittently along the length of the housing 26. This may be the case, for example, if the housing 26 is constructed from injection molded plastic. Also, by way of further example, portions of the end portion 84, outer wall portion 86, and closure flap 100 may be removed along the length of the housing 26 so that means, such as brackets, can extend through the housing to connect the housing, inflatable curtain 14, and fill tube 22 to the vehicle 12.

[0027] The end portion 84 of the housing 26 is positioned adjacent the roof rail 70 near the intersection of the side structure 16 and the vehicle roof 18. The outer wall portion 86 has a generally flat configuration and extends from the end portion 84 away from the roof 18 along an inner portion 78 of the roof rail 70. The bead 106 of the outer wall portion 86 is located at the terminal end of the second longitudinal edge 96 of the channel portion 80.

[0028] The closure flap 100 extends from the first longitudinal edge 94 away from the vehicle roof 18. The closure flap 100 includes a first portion 112 that is spaced from and extends generally parallel to the outer wall portion 86. The closure flap 100 also includes a second portion 114 that curves or is otherwise bent towards the second longitudinal edge 96. The bead 106 of the closure flap 100 is located at the terminal end of the second portion 114 of the closure flap. When the closure flap 100 is interconnected with the outer wall portion 86 via the beads 106, the bead of the closure flap is located in a concave slot 116 formed along the second longitudinal edge 96 adjacent the bead 106 of the outer wall portion 86.

[0029] The housing 26 also includes a deployment flap 120 that extends from an inner surface 124 of the outer wall portion 86, adjacent the second longitudinal edge 96, into the chamber 82 of the. channel portion 80. When the apparatus 10 is in the stored position of FIG. 4, the deployment flap 120 overlies the second portion 114 and a portion of the first portion 112 of the closure flap 100. The deployment flap 120 thus may overlie a major portion of the closure flap 100. The deployment flap 120 has a curved or bent configuration and extends along an inner surface 122 of the closure flap 100. As shown in FIG. 4, the curved or bent configuration of the deployment flap 120 may follow the contour of the first and second portions 112 and 114 of the closure flap 100.

[0030] The vehicle 12 includes a headliner 140 that extends along an inner surface 146 of the roof 18 of the vehicle. The headliner 140 has a portion 142 that extends at an acute angle relative to the roof 18 adjacent the housing 26. The portion 142 of the headliner 140 is positioned adjacent the closure flap 100. A terminal end 144 of the headliner is in abutting engagement with a trim piece 150 of the vehicle 12.

[0031] Those skilled in the art will recognize that the configuration of the vehicle structure and, thus, the spatial and interconnecting relationships between the vehicle structure and the headliner 140, trim piece 150 and housing 26 may vary depending upon the particular vehicle. Therefore, it should be recognized that the vehicle structure illustrated in FIGS. 4 and 5 and the spatial and interconnecting relationships between the vehicle structure and the headliner 140, trim piece 150 and housing 26 is for illustrative purposes and may vary without departing from the spirit of the present invention.

[0032] In the embodiment illustrated in FIG. 4, the trim piece 150 overlies the B pillar 32 of the vehicle 12 and is positioned generally adjacent and below the housing 26. Similar trim pieces (not shown) would also overlie the C pillar 34 (FIGS. 1 and 2) and a D pillar (not shown) of the vehicle 12. The configuration of the vehicle structure and the spatial and interconnecting relationships between the vehicle structure and the headliner 140, trim piece 150 and housing 26 at these locations would be similar to that illustrated in FIGS. 4 and 5. Therefore, FIGS. 4 and 5 illustrate the present invention as the present invention relates to the B pillar 32, C pillar 34, and the D pillar of the vehicle 12.

[0033] The vehicle 12 includes a sensor mechanism 170 (shown schematically in FIGS. 1 and 2) for sensing a side impact to the vehicle 12 and/or a rollover of the vehicle 12. The sensor mechanism 170 actuates the inflator 24 in response to the sensing of a side impact or a vehicle rollover. In the event of a rollover of the vehicle or a side impact to the vehicle 12 for which inflation of the curtain 14 is desirable, the sensor mechanism 170 provides an electrical signal over lead wires 172 to the inflator 24. The electrical signal causes the inflator 24 to be actuated in a known manner. The inflator 24 discharges fluid under pressure through fill tube 22, which directs the fluid into the inflatable curtain 14.

[0034] The inflatable curtain 14 inflates under the pressure of the inflation fluid from the inflator 24. The beads 106 on the outer wall portion 86 and the closure flap 100 separate under the pressure of the inflation fluid, and the housing 26 opens to the position illustrated in FIG. 5. The inflatable curtain 14 inflates away from the roof 18 in a downward direction as shown in the drawings and in a downward direction with respect to the direction of forward travel of the vehicle 12 into the position illustrated in FIGS. 2, 3 and 5.

[0035] When the housing 26 opens, the inflating curtain 14 causes the closure flap 100 (FIG. 5) to pivot or otherwise move in a direction generally away from the vehicle side structure 16 and roof rail 70 into the position illustrated in FIG. 5. As the closure flap 100 moves from the position of FIG. 4 to the position of FIG. 5, the closure flap engages the headliner 140 and causes the headliner to move in a direction generally away from the side structure 16 and roof rail 70 into the position illustrated in FIG. 5. This creates an opening 180 between the outer wall portion 86 and the closure flap 100 through which the inflatable curtain 14 may extend during inflation and while in the inflated condition.

[0036] As a feature of the present invention, the deployment flap 120 helps to deflect or otherwise direct the inflatable curtain 14 to inflate inboard of the trim piece 150, between the trim piece and any occupants of the vehicle. During inflation of the inflatable curtain 14, the deployment flap 120 is deflected or bent from the position illustrated in FIG. 4 to the position illustrated in FIG. 5. The deployment flap 120, when in the position illustrated in FIG. 5, extends inboard of the trim piece 150. Thus, as the inflatable curtain 14 inflates, the deployment flap 120 helps prevent the curtain from getting caught on the trim piece 150 or inflating between the trim piece and the side structure 16.

[0037] The closure flap 100 and the deployment flap 120 may extend substantially along the entire length of the housing 26. This may be the case, for example, if the housing 26 is constructed from extruded plastic. The deployment flap 120, however, may only be required adjacent the pillars of the vehicle 12. Thus, individual deployment flaps 120 may be spaced apart along the length of the housing 26 at positions adjacent the B, C and/or D pillars of the vehicle 12. This may be the case, for example, if the housing 26 is constructed from injection molded plastic, and the deployment flaps 120 are molded individually. As an alternative, in an extruded construction, portions of the deployment flap 120 positioned between the vehicle pillars could be cut away or otherwise removed so that deployment flaps are positioned only at locations adjacent the vehicle pillars.

[0038] The inflatable curtain 14 (FIG. 3), when inflated, extends along the side structure 16 of the vehicle 12 and is positioned between the side structure and any occupant 182 of the vehicle. As illustrated in FIG. 3, the inflatable curtain 14, when inflated, is also positioned between the trim piece 150 and the occupant 182 of the vehicle 12. When the inflatable curtain 14 is in the inflated condition, the first panel 40 is positioned adjacent the side structure 16 of the vehicle 12. The second panel 42 is positioned adjacent or near the vehicle occupant 182. The upper edge 50 (FIG. 2) is positioned adjacent to the intersection of the roof 18 and the side structure 16 of the vehicle 12. The front portion 54 is positioned adjacent to the A pillar 30 of the vehicle 12. The rear portion 56 of the inflatable curtain 14 is positioned adjacent to the C pillar 34 of the vehicle 12. The inflatable curtain 14 extends between the A pillar 30 and the C pillar 34 of the vehicle 12 and overlies at least a portion of the A pillar, C pillar, and the B pillar 32 of the vehicle.

[0039] It will be recognized by those skilled in the art that the inflatable curtain 14 may have alternative configurations. For example, in the illustrated embodiment, the inflatable curtain 14 extends between the A pillar 30 and the C pillar 34 of the vehicle 12. The inflatable curtain 14 could, however, extend between the A pillar 30 and the B pillar 32 only or between the B pillar and the C pillar 34 only. Also, in a vehicle having A, B, C, and D pillars (not shown), the inflatable curtain 14 could, when inflated, extend between the A pillar and the D pillar.

[0040] The inflatable curtain 14, when inflated, helps to protect a vehicle occupant in the event of a vehicle rollover or a side impact to the vehicle 12. The housing 26 and, particularly, the deployment flap 120 help to position the inflatable curtain 14, when inflated, between a vehicle occupant and vehicle trim pieces 150, which overlie the side structure. The inflatable curtain 14, when inflated, helps to absorb the energy of impacts with the curtain and helps to distribute the impact energy over a large area of the curtain.

[0041] A second embodiment of the present invention is illustrated in FIGS. 6 and 7. The second embodiment of the invention is similar to the first embodiment of the invention illustrated in FIGS. 1-5. Accordingly, numerals similar to those of FIGS. 1-5 will be utilized in FIGS. 6 and 7 to identify similar components, the suffix letter “a” being associated with the numerals of FIGS. 6 and 7 to avoid confusion. The apparatus 10aof the second embodiment of the present invention is identical to the apparatus 10 of the first embodiment (FIGS. 1-5), except that the housing 26aof the second embodiment (FIGS. 6 and 7) has a different configuration than the housing 26 of the first embodiment (FIGS. 1-5).

[0042] As illustrated in FIG. 6, the deployment flap 120aextends from the outer wall portion 86aat the second longitudinal edge 96aof the channel portion 80a.The deployment flap 120aextends along the closure flap 100aadjacent to an outer surface 220, opposite the inner surface 122a,of the closure flap. The deployment flap 120ais thus positioned outside the chamber 82a.The deployment flap 120ahas a curved or bent configuration and overlies the second portion 114aand a portion of the first portion 112aof the closure flap 100a.

[0043] The bead 106aon the closure member 100ainterlocks with a clasp 222 that extends from the inner surface 124aof the outer wall portion 86anear the second longitudinal edge 96a.The clasp 222 may be one of several individual clasps spaced along the length of the housing 26awith each clasp extending along a predetermined portion of the length of the housing. This may be the case, for example, if the housing 26 is constructed from injection molded plastic. Alternatively, the clasp 222 may extend along the entire length of the housing 26a.This may be the case, for example, if the housing 26ais constructed from extruded plastic.

[0044] When the inflatable curtain 14ais inflated, the deployment flap 120aoperates to help prevent the curtain from getting caught on the trim piece 150aor inflating between the trim piece and the vehicle side structure 16a.The deployment flap 120ahelps to deflect or direct the inflatable curtain 14ato inflate between the trim piece 150aand an occupant of the vehicle. During inflation of the inflatable curtain 14a,the deployment flap 120ais deflected or bent from the position illustrated in FIG. 6 to the position illustrated in FIG. 7. The deployment flap 120a,when in the position illustrated in FIG. 7, extends inboard of the trim piece 150a,which helps prevent the inflatable curtain 14afrom getting caught on the trim piece 150aor inflating between the trim piece and the side structure 16a.

[0045] The inflatable curtain 14a,when inflated, helps to protect a vehicle occupant in the event of a vehicle rollover or a side impact to the vehicle 12a.The housing 26a,particularly the deployment flap 120a,helps to position the inflatable curtain, when inflated, between a vehicle occupant and vehicle trim pieces 150awhich overlie the side structure. The inflatable curtain 14a,when inflated, helps to absorb the energy of impacts with the curtain and helps to distribute the impact energy over a large area of the curtain.

[0046] From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.