Abstract: An anchoring apparatus eliminates the need for an anchor plate and an anti-rattle member. The anchoring apparatus includes a flexible connector member which may be embodied as a strip of fabric material. An end of the connector member is disposed to form a loop and then attach to the remaining body of the connector member. The loop defines an anchor aperture which is configured to receive and retain an anchor bolt. The loop may further be configured with one or more twists to consolidate the connector member around the aperture. The twists allow the aperture to better engage and retain the anchor bolt due to the higher concentration of material. The attachment of the end to the connector member ensures retention of the twists in the loop. Attachment of the end is achieved by use of a fastener which may be embodied as stitches, adhesives, rivets, clips, staples and so forth.

Abstract: An apparatus is provided to reinforce an airbag while it is deploying through an airbag cover. An undeployed airbag is wrapped in a cover deployment flap that may be a thin piece of material. The cover deployment flap is located between the airbag and the airbag cover. As the airbag deploys, the cover deployment flap remains between the airbag and the airbag cover until the airbag cover is sufficiently open. The cover deployment flap may have multiple folded configurations to wrap the undeployed airbag. The cover deployment flap may further include an overlap that allows the airbag to release from the cover deployment flap once the airbag cover is open.

Abstract: An inflatable rigid knee airbag system for assisting in positioning and decelerating a vehicle occupant is disclosed. The system includes an inflatable knee airbag having a front panel, an annular, accordion-folded bellows panel, and a rear panel having an inflation orifice and mounting brackets; and a pyrotechnic inflator. The system helps to improve the kinematics of a vehicle occupant in relation to a primary airbag cushion by bolstering the knees of the occupant. The system of the invention may be mounted in a vehicle in a panel under the steering column, in the door of a glove box, or in the lower section of the instrument panel of the vehicle directly in front of the occupant's lower legs.

Abstract: The invention provides an effective and efficient method of making a hexammine cobaltic salt, such as hexammine cobaltic nitrate, in a consistent fashion through the control of one or more selected parameters of manufacture. Specific parameters considered and evaluated as a part of the invention included: order of addition of reactants, reaction temperature, oxidation, air or oxidant flow, catalyst content, and amount of ammonia.

Abstract: Ammonium nitrate is phase-stabilized by a synergistic phase stabilization additive combination of at least cupric oxide and potassium nitrate. Specifically, phase-stabilized ammonium nitrate contains between about 94.0 and about 96.0 wt. % ammonium nitrate and between about 4 and 6 wt. % of a synergistic phase stabilization additive combination of at least cupric oxide and potassium nitrate, wherein the cupric oxide is present in a relative amount of no more than about 2.0 wt. %. In some cases, additional stability is imparted by the inclusion of zinc oxide such as in a relative amount of no more than about 1.5 wt. %.

Abstract: The overhead airbag system includes an inflatable cushion and a fill tube. The inflatable cushion has a first and a second opening. The fill tube has an outlet and two open ends. The fill tube passes through the first and second openings. The outlet is positioned within the inflatable cushion and the two open ends are positioned outside the inflatable cushion. An inflation source is in fluid communication with both the open ends of the fill tube. Upon deployment, the inflation source generates inflation gas that passes through the fill tube and into the inflatable cushion through the outlet. During inflation, the fill tube expands to limit passage of inflation gas between the fill tube and the perimeter of the first and second openings. Following inflation, the fill tube at least partially separates from the perimeter of the first and second openings to enable inflation gas to exit the cushion.

Abstract: A flexible inflator provides enhanced features to an inflatable airbag restraint such as flexibility to facilitate installation in the tight spaces along the sides of a vehicle. The flexible inflator may include a housing with first and second ends made of corrugated metal. End caps are attached to each end of the cylindrical housing to form a pressure vessel. Combustible material, capable of generating inflation fluid, is positioned within a membrane inside the housing. An initiator is in communication with the combustible material, for initiating a combustible reaction within the housing. The housing is surrounded by a steel wire over-braid. The corrugated steel housing can be readily pierced without leaving a burr to damage the environmental seal. The corrugation also provides a plenum allowing gasses to readily flow from around the inflation fluid generant.

Abstract: A novel airbag module is described. The airbag module includes an inflatable cushion defining a mouth for receiving inflation fluid. A substantially cylindrical housing is configured to retain the inflatable cushion in a folded state. A disc-shaped inflation fluid source is attached to the housing and is in communication with the inflatable cushion. The inflation fluid source is positioned substantially within the housing and is configured to produce at least about 120 liters of inflation fluid volume. A flared retaining collar is positioned about the inflation fluid source adjacent an inner surface of the inflatable cushion to retain the inflatable cushion in communication with the inflation fluid source.

Abstract: An airbag or inflatable curtain inflator for producing two differing gas flows is disposed. The inflator has a gas chamber, a first orifice, and a second orifice. The first orifice has a different effective cross-sectional area than the second orifice. The two different cross-sectional areas allow the first orifice to produce a mass flow rate of gas that is different from the second orifice. The mass flow rates of gas may be related to the volume of an inflatable curtain into which the gas is ejected. Thus, two differently sized volumes of an inflatable curtain may be simultaneously inflated with a single inflator.

Abstract: A variable thickness vehicular airbag including a primary cushion and a contact cushion. The primary cushion is constructed of a top panel and a bottom panel joined to form a cushion. The contact cushion is joined to one of the panels of the primary cushion. The contact cushion may have an expansion panel and optionally an expansion sleeve. This cushion encompasses an opening in the outer panel and functionally increases the thickness and volume of the primary airbag. This airbag design may be useful in thorax airbags, thorax/pelvic airbags, thorax/head airbags, and inflatable curtain airbags to more effectively absorb the impact of an occupant with a wall of a vehicle during vehicular collisions.

Abstract: A novel mounting bracket for an inflatable curtain is described. The mounting bracket includes a pair of attachment plates for engaging respective sides of the inflatable curtain. One plate includes an opening through which a fastener may be positioned to secure the bracket and attached inflatable curtain to the interior of a vehicle. A bushing having an inner surface and an outer surface is positioned within the opening in the mounting plate. Flanges extending from an outer surface of the bushing maintain the bushing within the opening. The outer surface of the bushing is smaller than the opening which allows the bushing to rotate freely within the bracket when a fastener is used to secure the mounting bracket to the interior of a vehicle.

Abstract: An airbag inflator having two individual sections coupled together by a connection member is disclosed. The vessel may be configured to have different airbag inflation characteristics. The sections may have different gas generants, volumes, and orifice sizes. The inflator may also include modular components. Various vessels having different inflation characteristics may be attached to a connection member. The use of modular components allows multiple inflator configurations to be created from a smaller number of components.

Abstract: Attachment assemblies are provided for attaching airbag components, such as inflatable curtain modules and tethers, to surfaces inside a vehicle. The attachment assemblies may include a clip with a tapered stud having a circular or rectangular cross-sectional shape that can be pressed into a corresponding opening of the vehicle surface. Each of the tapered studs may have a plurality of branches designed to reduce the force required to insert the tapered stud into the corresponding opening. Additionally, each clip may have a flange with a contoured shape designed to fit closely to its associated vehicle surface and to position the airbag component properly for deployment. A tether may be routed, or removably attached to ensure positioning for proper deployment, through the use of one or more attachment assemblies that permit breakaway of the tether from each attachment assembly. Curtain modules may be more permanently affixed to the attachment assemblies.

Abstract: A folded rigid knee airbag for preventing the lower body portion of a vehicle occupant from being propelled forward during a collision is provided. The folded rigid knee airbag includes a back panel and a front panel attached to the back panel. Both the front panel and the back panel may be made from a rigid material, such as sheet metal. The back panel may include first and second accordion folds, and first and second vertical folds. The airbag may be in communication with an inflator. During discharge of the inflator, the accordion folds and the vertical folds unfold to form four substantially planar walls. The accordion folds and the vertical folds enable the front panel to remain substantially flat and maintain a substantially uniform cross-sectional area during inflation.

Abstract: Enhanced airbag covers and associated methods are disclosed. Each of the covers permits deployment of a compacted airbag cushion along multiple axes, thereby decreasing the relative momentum of the airbag and the vehicle occupant, and enhancing the ability of the cushion to protect vehicle occupants who are out of their nominal positions. Covers may include two frontal portions separated by a frontal seam that tears open to permit emergence of the cushion between the frontal portions. In addition, each cover may have a peripheral skirt that opens to permit emergence of the compacted cushion along additional axes. The peripheral skirt may have peripheral seams and connecting seams that facilitate opening of the skirt portion. The peripheral and connecting seams may be configured such that the peripheral skirt opens consistently, regardless of whether the frontal seam has separated.

Abstract: An inflatable curtain module is disclosed, where the inflatable curtain module has an inflator, and an inflatable curtain. The inflator may have a biaxial flow providing a gas input into two separate inflatable cushions. The cushions may be different sizes or volumes. Alternatively, other inflatable curtain modules may incorporate multiple inflators and multiple cushions to create an inflatable curtain module. The multiple inflators can be employed to provide two gas inputs into a single inflatable cushion. An inflatable curtain module may also be created from a number of generically sized cushions and inflators that are assembled into an inflatable curtain module for a wide range of vehicles.

Abstract: An airbag inflator system and method of manufacture is disclosed which may be stored in a small area, is simple to fabricate, directs exhaust gas from a standardized inflator, sufficiently cools and diffuses the exhaust gas, and catches hot gas generant residue. The system includes an airbag inflator within a sleeve. Solid sections of the sleeve circumscribe the inflator and are positioned to divert exhaust gas leaving an exit port of the inflator. The configuration of the solid sections provides that the inflator need not be rotated during assembly to position exit ports below solid sections. The diverted exhaust gas unrolls the sleeve to form an exhaust passage. The gas passes through the exhaust passage and is dispersed by the permeable section before entering the textile airbag. In this way, a simple, effective diffusion system for curtain airbag inflators is provided.

Abstract: An inflatable airbag cushion for protecting occupants of a vehicle in a side impact, rollover, or other crash situation is presented. The airbag cushion has at least two inflatable protection zones. Each protection zone is configured to protect an occupant in a different seat of the vehicle. An inflation channel receives pressurized gas from a source of pressurized gas and directs the gas into the inflatable airbag. Each protection zone is separated from any adjacent protection zones by a connection zone. At least one communication channel allows the pressurized gas to flow between the protection zones. The gas flow between protection zones allows the pressure within the separate protection zones to equalize. The airbag cushion may have three protection zones and is configured to protect an occupant of a vehicle having pillars A through D. The first, second, and third protecting zones for protecting an occupant seated in the front, middle, and rear seats of the vehicle respectively.

Abstract: An airbag inflator housing is disclosed that provides a multi-dimensional inflation surface. The housing may include a back wall, a front wall, and at least one side wall connecting the front wall to the back wall to enclose a volume within the housing. A nozzle array may be integrated with the front wall. The nozzle array may include a plurality of pre-formed and sealed nozzles. The nozzles may be arranged according to a two-dimensional array to provide an inflation surface to inflate a connected airbag. The nozzles may be formed using MEMS processes to provide very small and precise nozzles.

Abstract: A porous igniter body and a method of making the same are provided wherein a blowing agent component including at least one thermally decomposable blowing agent solid is mixed with at least one igniter fuel and at least one igniter oxidizer to form an igniter body precursor. The igniter body precursor is subsequently subjected to a temperature sufficient to decompose at least a portion of the blowing agent to form the porous igniter body.