Abstract: An apparatus for use with an inflatable vehicle occupant restraint (18) includes a chute structure (26) and a deployment door (24). The deployment door (24) has a pivotal door panel (100) and a flange (102) projecting from the door panel (100). The chute structure (26) and the flange (102) together define a chute passage (28) through which the restraint (18) moves outward toward the door panel (100) when inflating. The chute structure (26) includes a plurality of chute panels (150,152,154) having installed positions in which the chute panels (150,152,154) define peripheral sides of the chute passage (28). Adjacent pairs of the chute panels (150,152,154) are joined together along fold lines (170,172), and are pivotal about the fold lines (170,172) relative to each other for movement to their installed positions.

Abstract: A deployment door assembly (28) covers an inflatable air bag (12) contained in a reaction canister (24) in a vehicle (16). The deployment door assembly (28) is a part which has a panel portion (30), wall portions (180-188), and mounting portions (54). The panel portion (30) closes an opening (49) in the vehicle (16). The panel portion (30) has a peripheral edge surface (80), and includes a deployment door (32) which is spaced fully from the peripheral edge surface (80). The wall portions (180-188) direct the inflating air bag (12) to move outward from the reaction canister (24) toward the deployment door (32). The wall portions (180-188) surround the deployment door (32) and project inward from the panel portion (30). The mounting portions (54) mount the deployment door assembly (28) on the vehicle (16) at locations spaced from the reaction canister (24). The mounting portions (54) project inward from the panel portion (30) at locations between the wall portions (180-188) and the peripheral edge surface (80).

Abstract: A deployment door (24) for an inflatable air bag (18) has a door panel (80), a hinge (84), and first and second stress risers (128,192). The first stress riser (128) ruptures under stress induced in the door panel (80) upon movement of the air bag (18) forcefully against the door panel (80). The hinge (84) supports the door panel (80) for pivotal movement about an axis (190) when the first stress riser (128) has been ruptured. The hinge (84) includes a pivotal hinge leaf (150) having opposite side edges (180,182). One of the side edges (180) extends alongside the axis (190). The other side edge (182) is skewed relative to the axis (190). The second stress riser (192) ruptures under stress induced in the pivotal hinge leaf (150) when the door panel (80) pivots about the axis (190).

Abstract: An air bag module (12) includes an inflator (20), a canister (24) which contains the inflator (20), and an air bag (18). The air bag module (12) further includes a retainer assembly (26) which contains the air bag (18) in an uninflated condition. The retainer assembly (26) includes a pair of retainers (210,212) that are fastened together with an edge portion (192) of the air bag (18) retained between the retainers (210,212). The retainer assembly (26) and the canister (24) are fastened to each other in an assembled relationship in which an inlet opening (196) in the air bag (18) is aligned with an outlet opening (112) in the canister (24). The retainer assembly (26) and the canister (24) snap together into a mechanically interlocked condition when they are moved into their assembled relationship. The inflator (20) and the canister (24) also snap together into a mechanically interlocked condition when the inflator (20) is moved into the canister (24).

Abstract: A deployment door assembly (28) covers an inflatable air bag (12) contained in a reaction canister (24) mounted in a vehicle (16). The deployment door assembly (28) includes first and second continuous pieces of plastic material. The first piece defines a substrate (50) having a panel portion (56), first wall portions (170-174), and second wall portions (180-188). The panel portion (56) closes an opening (49) in the vehicle (16), and defines boundaries of a deployment door (32). The first wall portions (170-174) extend across the deployment door (32), and project inward from the deployment door (32). The second wall portions (180-188) surround the deployment door (32), and direct the inflating air bag (12) to move outward from the reaction canister (24) toward and against the first wall portions (170-174). The second continuous piece of plastic material defines an outer layer (52) which covers the substrate (50) in overlying surface contact.

Abstract: A deployment structure (28) for use with an inflatable vehicle occupant restraint (12) is rupturable by the restraint (12) when the restraint (12) is being inflated. The deployment structure (28) includes a plastic part (52). The plastic part (52) has a seam (158) along which it is rupturable under stress induced by movement of the restraint (12) forcefully against the deployment structure (28). The plastic part (52) includes first and second bodies (150,152) of plastic foam which are joined to each other at the seam (158). The first and second bodies (150,152) of plastic foam preferably have respective values of durometer hardness that differ from each other.

Abstract: A deployment door assembly (30) covers an inflatable air bag (12) in a vehicle. The deployment door assembly (30) is a part which has a panel portion (32) and a base portion (36). The panel portion (32) has a peripheral edge surface (74), and includes a deployment door (34) which is spaced fully from the peripheral edge surface (74). The base portion (36) directs the inflating air bag (12) to move outward toward the deployment door (34). The base portion (36) includes corrugated walls (180-186) which surround the deployment door (34) and project inward from the panel portion (32).

Abstract: A vehicle air bag module includes a new and useful tether structure for incorporating a cover into the air bag module. The tether structure enables the cover to separate from the remainder of the module but remain tethered to the air bag as the air bag is being deployed from the module.