Airbag fastener

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 60/483,974, filed Jul. 1, 2003, which is incorporated by reference herein.

[0002] The present invention relates to an airbag device. More particularly, the present invention relates to a side curtain airbag device that includes a non-adhesive retention mechanism for securing a side curtain airbag.

[0003] Side curtain (or side impact) airbag devices are designed to inflate to protect a vehicle occupant from a lateral impact with a side of the vehicle's interior. For example, side impact protection may be required when another vehicle collides with the side of the occupant's vehicle or when the occupant's vehicle loses control and rolls over causing the side of the vehicle to repeatedly impact the ground. During a rollover event, an inflated side curtain airbag may also prevent the occupant's head from emerging through a vehicle window opening.

[0004] Side curtain airbag devices are typically stored within a vehicle roof rail and are enclosed by interior trim work. In the stored state, a deflated side curtain airbag is folded and fastened to a bracket that is affixed directly to the vehicle structure. The airbag is often enclosed in a fabric casing (or bag cover) and may have a protector cloth disposed between the airbag and the bracket to protect the airbag from punctures. Conventional side curtain airbag devices typically include a retention mechanism configured to wrap around the folded airbag to secure the airbag in position against the bracket or to secure the protector cloth around the airbag. Adhesive tape is typically used as the retention member.

[0005] One disadvantage of conventional retention devices is that the tension and application consistency of tape is difficult to control, particularly in a high volume manufacturing environment. The resulting inconsistency reflects poorly on perceived product quality. Moreover, tape cannot be manufactured by the airbag manufacturer and must therefore be procured from vendors. However, commercial adhesives are expensive and add complexity and cost to the material procurement process.

[0006] Thus, a need exists for a cost-effective retention mechanism to improve consistency of side curtain airbag device construction and to improve uniformity of side curtain airbag device quality.

[0007] According to an aspect of the present invention, an airbag device is provided. The airbag device includes an airbag configured to inflate in an event of a vehicle emergency and a retention mechanism for securing the airbag in a folded storage position. The retention mechanism includes a strap wrapped around a portion of the airbag and a slit that engages a tab for securing the strap in position.

[0008] According to another aspect of the present invention, an airbag device is provided. The airbag device includes an airbag configured to inflate in an event of a vehicle emergency, a bracket for attaching the airbag to a vehicle structure, and a retention mechanism for securing the airbag in a folded storage position. The retention mechanism includes a strap wrapped around a portion of the airbag and a portion of the bracket.

[0028] FIGS. 1-4 show a first embodiment of an airbag device 10 according to the present invention. The airbag device 10 includes an airbag 20 and a retention mechanism 30.

[0029] The airbag 20 is configured to be stored in a vehicle in a folded state and to inflate in an event of a vehicle emergency to protect a vehicle occupant. The airbag 20 is preferably a side curtain airbag. When folded, the airbag 20 may optionally be encased in a cover, such a tube-shaped fabric casing or bag cover (not shown). The airbag 20 includes an airbag tab 24 for connecting the airbag 20 to a bracket 40. As shown in FIG. 2, the airbag tab 24 may be fastened to the bracket 40 with a fastener 45. The fastener 45 may be any suitable fastener but is preferably a rivet. The bracket 40 may then be attached to a vehicle structure, such as a roof rail or pillar, so that the airbag 20 is securely installed in the vehicle. Alternatively, the airbag tab 24 of the airbag 20 may be attached directly to the vehicle structure so that the bracket 40 is eliminated.

[0030] The retention mechanism 30 is configured to secure the folded airbag 20 in position against the bracket 40 without the use of an adhesive, such as tape. The retention mechanism 30 includes a fastening member 32 (shown in FIG. 3) and a strap 34 (shown in FIG. 4). The fastening member 32 and the strap 34 are connected to the bracket 40. For example, the fastening member 32 and the strap 34 may be connected to the bracket 40 by the fastener 45, as shown in FIG. 2. Alternatively, the fastening member 32 may be integral with the bracket 40, and the strap 34 may be integral with the airbag 20 or with an airbag casing or “sock.”

[0031] The fastening member 32 is preferably made of metal and is sized and shaped to accommodate placement of the airbag 20 in the vehicle. The fastening member 32 can be formed by any known method such as, for example, stamping. The strap 34 is formed of fabric. The fabric may be any fabric suitable for use in an airbag application but is preferably a woven, non-woven, or film material.

[0032] The strap 34 includes a first end 34a that is attached to the bracket 40, a second end 34b that is configured to engage the fastening member 32, and a central portion 34c disposed between the first end 34a and the second end 34b. When the strap 34 is attached to the bracket 40, the strap 34 is configured to wrap around a portion of the airbag 20 and to fasten to the fastening member 32, as shown in FIGS. 1 and 2. For example, the second end 34b of the strap 34 may include slots S configured to receive corresponding projections or tabs T disposed on the fastening member 32.

[0033] In operation, the fastening member 32, the strap 34, and the airbag 20 are connected to the bracket 40 by the fastener 45. The strap 34 is wrapped about the airbag 20 and fastened to the fastening member 32 by hooking the slots S over the bracket tabs T of the fastening member 32, as shown in FIG. 2. When the strap is wrapped about the airbag 20 and fastened to the fastening member 32, the airbag 20 is secured in position against the bracket 40. The strap 34 may also include a tear seam (not shown) to enable the strap 34 to rupture during inflation of the airbag 20 thereby enabling the airbag 20 to deploy.

[0034] The above-described embodiment is preferred for use with a side curtain airbag bracket.

[0035] FIGS. 5A-7 show a second embodiment of an airbag device 110 according to the present invention. The airbag device 110 includes an airbag 120 and a retention mechanism 130. The airbag device 110 is similar to the previous embodiment except the retention mechanism 130 does not include the fastening member 32. In contrast, the retention mechanism includes only a strap 134 configured to secure a protector cloth 122 about the airbag 120.

[0036] The strap 134 includes a first end 134a, a second end 134b, and a central portion 134c disposed between the first and second ends 134a and 134b. As shown in FIG. 7, the first end 134a of the strap 134 includes slots S1, and the second end 134b of the strap 134 includes slots S2. The slots S1 and S2 enable the strap 134 to attach to the airbag 120 so that the strap 134 can be secured about the airbag 120.

[0037] In operation, the protector cloth 122 is wrapped around a portion of the airbag 120 so that the protector cloth 122 is disposed between the airbag 120 and the bracket 140. The slots S1 of the strap 134 are engaged with airbag tabs 124 by inserting the airbag tabs 124 in the slots S1 (shown in FIG. 5A). The strap 134 is then wrapped about the airbag 120 and the protector cloth 122, and the airbag tabs 124 are inserted into the slots S2 (shown in FIG. 5B). After the slots S1 and the slots S2 are engaged with the airbag tabs 124, the airbag tabs 124 are connected to a bracket 140 with a fastener 145 such as a bolt (shown in FIG. 5C). In this manner, the strap 134 secures the protector cloth 122 about the airbag 120. The bracket 140 may then be connected to a vehicle structure to thereby securely install the airbag 120 in a vehicle.

[0038] The above-described embodiment is preferred for use with a side curtain airbag bracket having an anti-twist configuration.

[0039] FIGS. 8-10 show a third embodiment of an airbag device 210 according to the present invention. The airbag device 210 includes an airbag 220 and a retention mechanism 230. The airbag device 210 is similar to the previous embodiments except the retention mechanism 230 is configured to wrap about the airbag 220, a protector cloth 222, and a bracket 240.

[0040] The retention mechanism 230 includes a strap 234 with a first end 234a, a second end 234b, and a central portion 234c disposed between the first and second ends 234a and 234b. As shown in FIG. 10, the first end 234a of the strap 234 includes a slot S1, and the second end 234b of the strap 234 includes a slot S2. The slots S1 and S2 enable the strap 234 to attach to the airbag 220 so that the strap 234 can be secured about the airbag 220, the protector cloth 222, and the bracket 240, as shown in FIGS. 8 and 9.

[0041] In operation, the protector cloth 222 is wrapped around a portion of the airbag 220. The slot S1 of the strap 234 is engaged with a first airbag tab 224a by inserting the airbag tab 224a in the slot S1. The first airbag tab 224a is then connected to the bracket 240 with a first fastener 245a such as a bolt. The strap 234 is wrapped about the airbag 220, the protector cloth 222, and the bracket 240, as shown in FIG. 8, and a second airbag tab 224b is inserted into the slot S2. After the slot S2 is engaged with the second airbag tab 224b, the second airbag tab 224b is connected to the bracket 240 with a second fastener 245b such as a rivet. In this manner, the strap 234 secures the protector cloth 222 about the airbag 220 and secures the airbag 220 to the bracket 240. The bracket 240 may then be connected to a vehicle structure to thereby securely install the airbag 220 in a vehicle.

[0042] The above-described embodiment is preferred for use with a side curtain airbag bracket.

[0043] FIGS. 11-12 show a fourth embodiment of an airbag device 310 according to the present invention. The airbag device 310 includes an airbag 320 and a retention mechanism 330. The airbag device 310 is similar to the previous embodiments except the retention mechanism 330 is configured to engage a center bracket 340 to secure the airbag 320 to the center bracket 340.

[0044] The retention mechanism 330 includes a strap 334. The strap 334 has a Y-shaped configuration, as shown in FIG. 12. The strap 334 includes a first leg 334a, a second leg 334b, and a central portion 334c disposed between the first and second legs 334a and 334b. The first and second legs 334a and 334b are configured to connect to the bracket 340. For example, an end of the first leg 334a includes a slot S1, and an end of the second leg 334b includes a second slot S2. The slots S1 and S2 enable the strap 334 to engage with hooks or tabs T disposed on an underside of the center bracket 34, as shown in FIG. 11A.

[0045] In operation, the slot S1 is engaged with a first bracket tab T of the center bracket 340 by inserting the first bracket tab T in the slot S1. Similarly, the slot S2 is engaged with a second bracket tab T by inserting the second bracket tab T in the slot S2. Bag cover hooks (not shown) may then be secured over the bracket tabs T, and then a protector cloth 322 may be folded into place. An airbag tab 324 and the central portion 334c of the strap 334 are then fastened (e.g., riveted) with a fastener 345 to an upper portion of the center bracket 340, as shown in FIG. 11. In this manner, the strap 334 secures the airbag 320 and the protector cloth 322 in position against the center bracket 340. The center bracket 340 may then be connected to a vehicle structure to thereby securely install the airbag 320 in a vehicle.

[0046] The above-described embodiment is preferred for use with a side curtain airbag center bracket for attaching a side curtain airbag to a B pillar.

[0047] FIGS. 13 and 14 show a fifth embodiment of an airbag device 410 according to the present invention. The airbag device 410 includes an airbag 420 and a retention mechanism 430. The airbag device 410 is similar to the previous embodiments except the retention mechanism 430 is configured to engage a rear bracket 440 to secure the airbag 420 to the rear bracket 440.

[0048] The retention mechanism 430 includes a strap 434. The strap 434 includes a first end 434a and a second end 434b, as shown in FIG. 14. The second end 434b of the strap 434 includes a slot S configured to connect to the bracket 440. For example, the slot S may be sized to fit over a lower mounting feature 342 of the rear bracket 340, as shown in FIG. 13. Thus, the lower mounting feature 342 functions as a bracket tab that is received in the slot S.

[0049] In operation, the slot S of the strap 340 is engaged with the lower mounting feature 342 of the rear bracket 340 by inserting the lower mounting feature 342 in the slot S. The airbag 420 and a protector cloth 422 are folded into place. An airbag tab 424 and the first end 434a of the strap 434 are fastened (e.g., riveted) with a fastener 445 to the rear bracket 440, as shown in FIG. 13. In this manner, the strap 434 secures the airbag 420 and the protector cloth 422 in position against the rear bracket 440. The rear bracket 440 may then be connected to a vehicle structure to thereby securely install the airbag 420 in a vehicle.

[0050] The above-described embodiment is preferred for use with a side curtain airbag rear bracket.

[0051] FIG. 15 shows a sixth embodiment of an airbag device 510 according to the present invention. The airbag device 510 includes a airbag 520 and a retention mechanism 530. The airbag device 510 is similar to the previous embodiments except the retention mechanism 530 does not include a strap having a slot that engages a tab. Instead, the retention mechanism includes a strap 534 that is fastened about the airbag 520 and an energy absorbing member 540 by sewing.

[0052] As shown in FIG. 15, the strap 534 is wrapped about the airbag 520 and the energy absorbing member 540. The ends of the strap 534 are secured together by a sewing to form a sewn seam 534a. The seam 534a is positioned to enable the airbag 520 to deploy through the seam 534a. In this manner, the strap 534 secures the airbag 520 to energy absorbing member 540. The strap 534 may also include an aperture 534b so that an identification label affixed to the energy absorbing member 540 can be viewed through the strap 540.

[0053] Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is to be defined as set forth in the following claims.