Apparatus and method for airbag curtain module with secondary attachment device

[0001] 1. Field of the Invention

[0002] The present invention relates to an airbag curtain module with a secondary attachment device. More specifically, the present invention relates to a novel apparatus and method for securing two separate longitudinal portions of a folded airbag curtain to the interior of a vehicle.

[0003] 2. Description of Related Art

[0004] Inflatable safety restraint devices, or airbags, are mandatory on most new vehicles. Airbags are typically installed as part of a system with an airbag module in the steering wheel on the driver's side of car and in the dashboard on the passenger side of a car. In the event of an accident, a sensor within the vehicle measures abnormal deceleration and triggers the ignition of an explosive charge contained within an inflator. Expanding gases from the charge travel through conduits and fill the airbags, which immediately inflate in front of the driver and passenger to protect them from harmful impact with the interior of the car. Airbag systems have also been developed in response to the need for similar protection from lateral impacts between a passenger and the side of a vehicle's interior. This might occur when another vehicle collides with the side of the car, or in a rollover situation where the side of car is repeatedly impacting the ground.

[0005] Side impact airbag systems are designed to prevent the head of a vehicle occupant from emerging through the window opening or from colliding with the reaction surface at the side of the vehicle. Side impact airbags have a smaller area than front impact airbags in which to deploy and must be configured to inflate efficiently and in the right direction. There is also less space to install side impact airbags. Side inflatable airbag curtains are typically attached to the roof rail of a car behind the head liner. The roof rail is the metal portion of the car frame which extends along the side of the car at the junction of the side doors and the roof. The head liner is an interior component which covers the roof rail at the door seal.

[0006] Side airbag modules typically include an inflatable curtain folded into a predetermined configuration and then placed in a covering, wrap, or housing. Most side airbag modules include a single attachment means for securing the airbag module to the roof rail. When the airbag curtain is in a folded state, the airbag module is long, narrow, and flexible. The problem with most side impact air modules is that their long and narrow configuration makes them awkward and clumsy to install. The folded airbag must be positioned next to the roof rail or other frame member to which it will be attached. Often times, the roof rail is curved, and the installer needs both hands to align the somewhat flimsy folded airbag and module with the curved or twisted roof rail. This makes it extremely difficult if not impossible for the installer to operate the tool used to mount the airbag curtain to the vehicle. Sometimes this problem is overcome by using separate positioning equipment, or using multiple people to install the airbag curtain. Unfortunately, the use of additional equipment, tools, or human resources drives up the cost of installation. If the installer were to use one hand to steady the airbag curtain and the other hand to secure a portion of the curtain to the vehicle interior, the folded airbag curtain may bend, fold, or crimp, which may negatively effect the fold configuration of the airbag causing the airbag to inefficiently or improperly deploy upon inflation.

[0007] Another problem with known airbag modules stems from the fact that most roof rails to which the folded side impact airbag module is to be attached are not completely vertical. They are long angled pieces and even after a primary attachment area of the folded curtain is secured to the vehicle interior, the wrapped or covered curtain dangles down and away from the roof rail to which it is to be attached. The dangling airbag curtain module interferes with the assembly of the final interior trim. Additionally, side airbag curtain modules have less space in which to be installed, and it is preferable that they are installed in their most compact form. Dangling airbag curtain modules are not compact.

[0008] Thus, it would be an advantage to provide an airbag curtain module which allowed the installer to secure the primary attachment source to the interior of a vehicle without the need for extra tools, equipment, or human resources. It would also be an advantage to provide such an airbag curtain module that would allow the folded airbag to be pivoted out of the way and attached to the frame of a vehicle such that packaging and assembly of the final interior trim of the vehicle could be easily accomplished without interference from the folded inflatable curtain. It would also be an advancement to provide such an airbag curtain that was less expensive and easier to install.

[0009] Such an airbag curtain module and method of folding are disclosed and claimed herein.

[0010] The apparatus of the present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available inflatable airbag curtains and curtain folding methods. Thus, it is an overall objective of the present invention to provide a novel airbag curtain module and method for attaching an airbag curtain module which allows for more cost effective and easier installment than was possible with prior art systems.

[0011] To achieve the foregoing and other objectives, and in accordance with the invention as embodied and broadly described herein, an airbag curtain module with a novel attachment configuration is provided. The airbag curtain module includes an inflatable curtain which has a first edge and a second edge. The inflatable curtain can be positioned in a number of folded configurations when in an uninflated state. The airbag curtain module may include a covering for partially or fully enclosing the inflatable curtain. At least one and preferably several first attachment members are spaced along the first edge of the curtain. These first attachment members may include openings for a connector to secure a first portion of the module to the interior of a vehicle. The first attachment members may include tabs which extend through the covering when the covering is positioned about the folded airbag curtain.

[0012] At least one, and preferably multiple second attachment members are secured to an out-board side of the covering. When the covering is positioned about the folded airbag curtain, at least one of the second attachment members is positioned between at least one of the first attachment members and a bottom portion of the covering or module in locations anywhere along the longitudinal direction. Thus, the second attachment member may secure a second portion of the module between the first portion and a bottom portion of the module, when the first portion of the module is secured to the interior of the vehicle. This allows the module to be installed in closer conformity to the vehicle interior for greater compactness.

[0013] In one embodiment, the second attachment member includes a substantially flat magnet sewn into a pocket or affixed by any other attachment means on the outboard side of the cover. A plurality of magnets may be spaced adjacent to, and beneath the first attachment members or anywhere along the outboard side of the curtain when the covering is positioned about the curtain.

[0014] Each magnet has a magnetic field strength which permits the module to be secured to a vehicle interior and which also permits the detachment of the magnet from a vehicle interior with minimal force applied by a user. Thus, the user may opt to generally position the module against the vehicle roof-rail and temporarily secure the module with the magnets while securing the first attachment members in place. The magnets also allow the module to be removed without leaving residue or holes along the vehicle interior.

[0015] These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

[0021] The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method of the present invention, as represented in FIGS. 1 through 4, is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.

[0022] With particular reference to FIG. 1, an airbag module utilizing the present invention is generally designated at 10. The airbag module 10, includes an inflatable curtain 12 having a first edge 14 and a second edge 16. The curtain 12 is typically configured of 2 pieces of semi-permeable material attached to each other by means known in the art. The pieces may be attached to each other at seams 18 to form distinct chambers 20, each of which will retain inflation fluid such as gas produced by an inflator (not shown).

[0023] The airbag module 10 also includes a covering 22. The covering 22 is preferably configured to at least partially enclose the inflatable curtain 12 in a folded state. The covering 22 may be substantially as long as the curtain 12. In the preferred embodiment of the curtain 12 illustrated in FIG. 1, the covering 22 is attached to the curtain 12 along a stitch line 24. The covering 22 may be configured to permit a first edge 26 of the covering 22 to be attached along a second edge 28 of the covering 22 about the curtain 12 when the curtain 12 is in a folded state.

[0024] The curtain 12 includes a plurality of first attachment members 30 spaced along the first edge 14 of the curtain, the first attachment members 30 allow a first portion 32 of the module 10 to be secured to the interior of a vehicle. The first attachment members 30 may be configured with an opening 31 to receive a connector such as a screw, bolt, rivet, pin and the like, for attaching the module 10 to a roof rail of the vehicle interior. In an alternative embodiment, the first attachment members 30 may be attached to the vehicle interior by adhesive, bonding, welding, and the like. In the embodiment illustrated in FIG. 1, the attachment members are tabs 30. The tabs 30 extend from the first edge 14 of the curtain airbag 12 such that after the curtain 12 is in a fully folded state, the curtain 12 can be attached to the roof rail or other interior component of the vehicle (see FIG. 3).

[0025] The covering 22 includes at least one and preferably a same number of slots 34 as the number of tabs 30. The slots 34 are positioned and configured to receive the attachment tabs 30. It will be appreciated that in this configuration, the curtain 12 may be folded and enclosed by the covering 22, and still leave the attachment tabs 30 accessible for attachment of the curtain 12 to the interior of the vehicle. The attachment tabs 30 also allow the curtain 12 to be inflated without interference from whatever means may be used to attach the curtain 12 to the vehicle. In another embodiment, the first attachment members 30 may be connected to or secured to part of the covering 22 itself. In this configuration, there would be no need for the slots 34.

[0026] At least one second attachment member 36 is positioned near the first attachment members 30. A plurality of second attachment members 36 may be positioned substantially parallel to the first attachment members 30. In the embodiment, illustrated in FIG. 1, the second attachment members 36 are secured to the covering 22 such that when the covering 22 is secured about the folded curtain 12, and the module 10 is secured to the interior of a vehicle, the second attachment members 36 are below or adjacent to the first attachment member 30.

[0027] Referring now to FIGS. 2 and 3, the module 10 is illustrated in a folded configuration with the covering 22 secured about the folded airbag curtain 12. The plurality of second attachment members 36 are spaced along an out-board side 38 of the covering 22. The first attachment members 30, which in one embodiment extend from the first edge 14 of the curtain 12, extend through slots 34 in the covering 22. In the illustrated embodiment, the second attachment members 36 are aligned with the first attachment members 30. When the airbag module 10 is secured to the interior 40 (FIG. 3) of a vehicle the second attachment members 36 are secured to the covering 22 are positioned below the first attachment members.

[0028] The second attachment member 36 is configured to secure a second portion 52 of the module 10 to the interior 40 of the vehicle when the curtain 12 is secured within the covering 22. The second portion 52 is between the first portion 32 and a bottom portion 54 of the module 10 when the module 10 is secured to the interior 40 of the vehicle. Because the module 10, with the curtain 12 retained in a folded state, is long and narrow, the first portion 31 is a longitudinal portion adjacent the first attachment members 30 and the second portion 52 is also a longitudinal portion adjacent the second attachment members 36. Accordingly, once the first portion 31 of the module 10 is secured to the vehicle interior, the module 10 may be pivoted out of the way and attached at the second portion to the interior 40 by the second attachment members 36 (see FIG. 4). The dual attachment configuration allows the module 10 to be compactly and efficiently secured within the vehicle.

[0029] The second attachment member 36 comprises a magnet 44 positioned within a pocket 46. The magnet 44 is substantially flat and thin for compactness. A plurality of magnets 46 are spaced near the first edge 14 of the inflatable curtain 12. Each magnet 44 may be positioned opposite to, and adjacent to, one of the plurality of first attachment members 30. In a preferred embodiment, the pockets are configured along an outboard side 38 of the covering 22. The magnet 44 has a magnetic field strength which permits the detachment of the magnet 44 from a vehicle interior 40 with minimal force applied by a user. It will be appreciated by those of skill in the art that this allows the module 10 to be detached from the vehicle interior 40 in certain applications without leaving a noticeable hole, mark, or residue at the vehicle interior 40 adjacent the second portion 52 of the module 10.

[0030] Each pocket 46 may be positioned along an exterior surface 48 of the outboard side 38 of the covering 22 or along an interior surface 50 of the outboard side of the covering 22. The pockets 46 may be sewn to the covering 22 using nylon thread. In the illustrated invention, number 46 nylon thread is used at six to eight stitches per inch. It will be appreciated by those of skill in the art that the covering 22 may be attached to the curtain 12 in a variety of ways, including but not limited to, adhesive bonding, chemical bonding, heat welding, RF welding, and swaging. The curtain 12, covering 22, and pocket 46 may be constructed of suitable materials including, but not limited to woven polymeric yarn fibers, such as nylon or polyester. Nylon 6 and nylon 6_—6 are examples of preferred yarn materials. Other conventional yarns can be used in the fabric layer, typically having a denier ranging from about 210 to 630. The weave density will vary depending upon the desired fabric permeability and the yarn denier. For a typical 420 denier yarn, the weave density will range from 46×46 yarns per inch to 53×53 yarns per inch. Other suitable materials may include non woven nylon, including Cerex PBN II at 3 ounces per square yard. The curtain 12, covering 22 and pocket fabric may be coated with an impermeable coating on the interior surface (not shown) of the fabric. Currently preferred coating materials include, but are not limited to, urethanes and silicone/urethanes. Other known and novel fabric coating materials can be used. Once the magnets 44 are positioned within the pockets 46, a stitch may be placed at a pocket opening 47 to secure each magnet 44 within a respective pocket 46.

[0031] In an alternative embodiment, the second attachment member 36 includes an adhesive attached to the covering 22 sufficient to adhere the covering 22 to the vehicle interior 40. The second attachment member 36 may also include a clip attached to the covering 22 configured for attachment of, the covering 22 to the vehicle interior 40. The second attachment member 46 may be secured relative to the first attachment member 30 in a number of ways and still allow the module 10 to be pivoted into a more compact position. For instance, the second attachment members 36 may be offset from the first attachment members 30. Furthermore, the number of second attachment members 36 need not equal the number of first attachment members 30. At least one second attachment member 30 should be spaced from the first attachment members is the transverse direction to allow for two separate longitudinal areas to be attached to the vehicle interior 40. In this configuration, the outboard side 38 of the folded module more closely conforms to the configuration of the vehicle interior 40 to which the module 10 is being attached.

[0032] Referring now to FIG. 4, the curtain 12 of the airbag curtain module 10 is first folded into a predetermined configuration. The covering 22 may then be secured about the folded curtain 12. The module 10 is secured by means of the first attachment members 30 to the interior 40 of a vehicle and then the second attachment members 36 are secured to the vehicle interior at a position below the first attachment members 30. In this configuration, the second longitudinal portion 52 of the module is below the first portion of the module allowing the module to be attached in close conformity to the shape of the interior 40 piece to which the module 10 is to be secured. Where the second attachment members are magnets, the second attachment member 36 is positioned adjacent a metallic surface to permit the magnetic force of the magnet to secure the module to a vehicle interior. The installer may also decide to first use the magnet 44 or second attachment member 36 to loosely position the module 10 along the roof-rail of the vehicle interior 40 so that it is substantially in place. The installer then has both hands free to secure the first attachment members 30 to the interior 40. The installer may position the second attachment members 36 in their final position.

[0033] The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.