Abstract: Methods, apparatus, and systems for packing or deploying airbag cushions, such as driver side airbag cushions, to improve unfolding kinematics and/or otherwise improve performance. In some implementations of methods for packing an airbag cushion, a first portion of an airbag cushion may be compressed and then secured in a compressed configuration using a first wrap. A second portion of the airbag cushion may then be compressed and secured in a second compressed configuration using a second wrap. The resulting airbag cushion assembly may be configured to separate the wraps sequentially, rather than simultaneously, during inflation of the airbag cushion.

Abstract: An airbag assembly may include an inflatable airbag with a stowed configuration and a deployed configuration, and a restraint member that keeps the inflatable airbag in the stowed configuration. The restraint member may have a frangible portion designed to tear at a pre-established threshold level of tension to permit deployment of the inflatable airbag. The frangible portion may have material that has been pre-stressed such that it has a lower strength than surrounding material. In one example, pre-stressing may be carried out by forming a crease in the frangible portion and, optionally, subjecting the frangible portion to compressive stress. When the airbag deploys, the frangible portion may predictably tear to release the airbag. The airbag assembly may be an inflatable curtain airbag, and the restraint member may one of a plurality of wrappers distributed along the length of the inflatable curtain airbag to encircle it in the stowed configuration.

Abstract: An airbag assembly may include an airbag with a first fabric panel, a second fabric panel attached to the first fabric panel, and a third fabric panel attached to the second fabric panel. The first and second fabric panels may define a first inflatable cushion and the second and third fabric panels may define a C-shaped second inflatable cushion. Upon deployment, the first inflatable cushion may have a first pressure and the second inflatable cushion may have a second pressure greater than the first pressure. Further, the first inflatable cushion may be positioned directly outboard of the thoracic region and the second inflatable cushion may be positioned directly outboard of the acromial region and the coxal region, but not the thoracic region, to provide gentler cushioning for the thoracic region.

Abstract: An airbag cushion assembly can include a mounting assembly and an airbag cushion. The mounting assembly includes a plate which may be coupled to the airbag cushion, and which may also include a fastener which is used to attach the assembly to a vehicle.

Abstract: A duplex harness assembly for a motor vehicle airbag occupant restraint system. The system design incorporates a connector housing for connection via a cable with a restraint system controller. The connector housing having an integrated circuit provides a duplex restraint system control. The duplex control is provided by incorporating one or more electronic elements such as diodes mounted to the circuit. One or more electronic device attachments are remotely mounted from the connector housing via pairs of conductive wires.

Abstract: A pyrotechnic inflator assembly including a shell member and an end cap joinable with the shell member to form a subassembly. The subassembly contains a quantity of pyrotechnic material and at least in part defines a combustion chamber wherein at least a portion of the quantity of pyrotechnic material is reactable to form product gas for inflation of an associated airbag cushion and to generate pressure therewithin. A diffuser assembly can be disposed adjacent an end of the shell member and includes flow control features for controlling flow of product gas from the inflator assembly. The inflator assembly further includes a composite overwrap about at least a portion of the subassembly and the diffuser assembly such that the pyrotechnic inflator assembly can withstand the pressure generated within the combustion chamber upon reaction of the pyrotechnic material. Corresponding methods of making a pyrotechnic inflator assembly are also provided.

Abstract: A gas generating pyrotechnic composition that in addition to a primary fuel component and a primary oxidizer component includes critical relative amounts of elemental carbon and cupric oxide. Also provided are associated methods for producing an inflation gas for an occupant restraint system of a motor vehicle.

Abstract: A sensor assembly for a motor vehicle adapted for sensing impacts including pedestrian impacts. The sensor assembly integrates functions of pressure based sensors used in one embodiment with a compressible tube extending laterally across the front surface of the vehicle and the outboard front boundary areas of the front end of the vehicle. Both acceleration and pressure based sensors are mounted into an integrated sensor housing which is mounted in a desired position at the vehicle front fascia front boundary areas. The system optimizes pressure based sensing while providing acceleration based sensing at the lateral boundary areas where supporting structure does not enable pressure based sensing. The invention further including sensor arrangements including discrete pressure and acceleration sensors deployed for detecting pedestrian impacts at the center and front boundary areas of the vehicle front end.

Abstract: An initiator assembly can include an outer body can have a first end, a second end, and an internal passage between the first and second ends. An initiator canister can be joined to the outer body at the first end and can define a charge chamber that includes a pair of pins extending therefrom. An insulative material can be molded within the passage to form an insulative structural member that joins the canister and pins to the outer body and insulates the pins and a portion of the canister from electrical contact with the outer body. An electrostatic discharge dissipater can be formed from an electrically conductive material and can be molded to the outer body. The dissipater can provide a controlled dissipation path for electrostatic discharge energy carried by the initiator assembly.

Abstract: The seatbelt pretensioner, which is designed for reducing slack in seatbelt webbing upon deployment in response to a triggering event, comprises an igniter that generates gas in response to the triggering event, an elongate body defining a chamber for receiving and the confining gas generated by the igniter, a piston movable within the elongate body by the gas generated, a slack-reducing assembly that responds to movement of the piston and is connected to at least a portion of seatbelt webbing, movement of the piston causes the slack-reducing assembly to move the seat belt webbing reducing slack in the seatbelt webbing; and a controlled pressure release that enables gas to escape from the elongate body after deployment, relieving gas pressure within the pretensioner.

Abstract: A side airbag module assembly for a vehicle seat back rest features a molded plastic cover (22) with a Class A surface constituting the outside of the cover visible after installation in the backrest (60). An airbag holder portion (24) made of plastic is molded onto the cover (22). The airbag holder portion (24) is formed as a fastening bracket (34). An airbag (15) including a gas generator (14) is prepackaged in a soft pack (12) with fasteners (20) protruding from the soft pack (12). The fasteners (20) and the fastening bracket (34) are configured to attach the soft pack (12) to the airbag holder portion (24). Upon deployment of the airbag, the fastening bracket (34) will bend and thereby open the cover (22), which allows the airbag (15) to inflate in a forward direction.

Abstract: An igniter for a passenger vehicle safety airbag module includes a housing with apertured walls, gas-generating tablets filling the housing, and, in direct contact with gas-generating tablets, an initiator containing combustible material. A plurality of four malleable flaps of substantially identical shape and size are secured about the squib in an upstanding circumscribing array with spaced-apart, opposed lateral edges between adjacent of the flaps interconnected by fluid seals in the form of webbing that is structurally less robust than the flaps. The ends of the flaps remote from the squib curl radially inwardly into a spaced-apart edge-to-edge disposition beyond the combustible material. The webbing and the flaps together enclose an interior space and the combustible material. Pressure from the ignition of the combustible material causes the fluid seals to burst and the flaps to pivot outwardly crushing the gas-generating tablets in the housing.

Abstract: An airbag assembly may include an inflatable curtain airbag with a stowed configuration and a deployed configuration. The inflatable curtain may have a first protection zone and a second protection zone that inflates forward of the first protection zone to provide enhanced protection. The second protection zone may be double-folded against the first protection zone so that, during deployment, the second protection zone pivots to unfold relative to the first protection zone. The airbag assembly may have a restraint member in the form of a forward tether or a first tether secured to the forward tether such that the restraint member exerts outboard force on the second protection zone during deployment to help control deployment of the second protection zone. Portions of the first and second protection zones may be fold-over sewn together to control the angle at which the second protection zone unfolds relative to the first protection zone.

Abstract: Air bag cushion inflators can include a body including a base member coupled to a diffuser member, the diffuser member including a sidewall with exit ports and a ceiling. A combustion chamber may be positioned within the body and includes a cap with an opening formed therein. A filter element may be positioned in fluid communication with the opening in the combustion chamber cap, and located between the combustion chamber cap and the diffuser member ceiling. The filter element includes at least one barrier and a plurality of apertures positioned to cause inflation gas from the combustion chamber to travel from the opening in the combustion chamber cap to the exit port along a tortuous path including at least one debris pocket and at least one impact region. Methods of forming a filter, and disposing the filter in an inflator body. Other aspects, embodiments, and features are also included.

Abstract: An airbag assembly may include an airbag cushion that can be deployed to cover a portion of the dashboard of a vehicle adjacent another portion of the dashboard that is covered by a deployed front airbag. In some embodiments, airbag cushions may be housed beneath a seating surface of an occupant and deploy inboard of the housing to cover a portion of the dashboard. Such airbags may provide increased protection to front seat occupants who move in an oblique direction, both forward and inboard, during a collision event.

Abstract: An airbag can include a panel that defines at least a portion of an inflatable chamber. The airbag can also include a slit vent that is at least partially defined by the panel. One or more seams can encompass the slit vent and can permit the slit vent to naturally be in a closed orientation.

Abstract: An inflatable curtain airbag system can include a first inflatable curtain airbag, a second inflatable curtain airbag, and a reinforced region. In some arrangements, the reinforced region may include a region where a portion of the first inflatable curtain airbag overlaps a portion of the second inflatable curtain airbag. In other arrangements, the reinforced region may include a region where either or both of the first and second inflatable curtain airbags comprise a localized region of increased stiffness.

Abstract: An airbag, or inflatable cushion assembly, can include an inflatable cushion and a throat liner. The throat liner can be coupled to an interior surface of the inflatable cushion at one or more coupling sites. The one or more coupling sites can include one or more panels that can be coupled to at least a portion of both of the inflatable cushion and the throat liner. The one or more panels can be configured to control or inhibit egress of an inflation gas at the one or more coupling sites.

Abstract: An airbag, or inflatable curtain airbag assembly, can include one or more chambers and vents. The vents can be in fluid communication with one or more of the chambers. The vents can be configured to delay passage of inflation gas from an interior of the airbag into an interior chamber or to an exterior of the airbag upon deployment of the airbag. The vents can also be configured to transition from a closed configuration to an open configuration when an internal pressure of the airbag reaches a predetermined value.

Abstract: A seatbelt anchor assembly includes a ferrule, a cable, and seatbelt buckle. The ferrule can be mounted at one end to a seat base or other mounted structure of the vehicle, and can further include an anti-rotation pin that is received in a locating hole of the seat base to limit rotation of the ferrule during mounting and during normal occupant use. The pin can be made from aluminum or other material that can shear off in response to a dynamic vehicle load, allowing the ferrule to pivot about its mounting location to align the loads. The ferrule can be in the form of a blank including a body portion and a head portion having a pair of ears, and can include a recess between the ear portions and the body portion to limit tension in the ferrule when the ferrule is crimped to mount a cable thereto.