Abstract: A single increment initiator charge for use in an inflatable restraint system and a method of preparing the single increment initiator charge are provided. The single increment initiator charge includes a homogeneous blend of zirconium, an oxidizer such as potassium perchlorate, and a combustion enhancer such as titanium hydride in an amount effective to result in the single increment initiator charge being effective to ignite an associated pyrotechnic charge. The single increment initiator charge may be formed by preparing a homogeneous blend such as by dry-blending the constituents or by mixing the constituents with a solvent such as an alcohol to form a slurry, loading the homogeneous blend into a charge holder and compressing the homogeneous blend.

Abstract: Inflation apparatuses and methods are provided wherein a hydrocarbon-containing inflation gas-producing mixture is formed via the fluid extraction of the hydrocarbon from a substrate material.

Abstract: A linear actuator with an internal dampening mechanism is disclosed. The actuator has a housing has a first end and a second end and forms an internal chamber. A constricted opening is also added to the actuator at the first end. A piston is disposed within the housing and is capable of sliding along the chamber. The piston has a head portion and a shaft portion. The shaft portion is slidable through the constricted opening whereas the head portion is not slidable through the constricted opening. A fluid is also added to the actuator. The fluid is disposed within the housing. In one embodiment, the actuator is constructed such that the sliding of the shaft portion forces a fluid through the constricted opening such that the movement of the piston is dampened. In an alternative embodiment, the actuator includes one or more second pistons and an orifice.

Abstract: A pyrotechnic inflator for an airbag module is disclosed. The pyrotechnic inflator may have a generally tubular housing that contains an initiator, a baffle, and a quantity of inflation gas generant. The generant is disposed in a compartment defined by the baffle. The baffle has a passageway with a first end and a second end. Direct fluid communication between the first and second ends is restricted by a blockage within the passageway. Upon receipt of an activation signal, the initiator directs initiation gas into the first end. The initiation gas may exit the first end through a plurality of first end holes to reach and ignite the generant with or without requiring any intermediate igniter material. The generant combusts to produce inflation gas, which enters the second end of the passageway through a plurality of second end holes. The inflation gas exits the inflator to inflate a cushion.

Abstract: A flexible member sensor for detecting motion and tension of a flexible member includes a rigid member pivotally connected to a base, in contact with the flexible member. A sensor detects pivotal motion of the rigid member in response to movement of the flexible member. The sensor may provide a corresponding signal to a motion control system that adjusts the tension of the flexible member accordingly. In one implementation, the flexible member sensor is integrated with a feedback control system for an electric seat belt retractor that includes a feedback control loop. The flexible member sensor measures tension in seat belt webbing retained by the retractor. A motor coupled to a servo amplifier rotates a spool of the electric retractor to extract or retract webbing in accordance with the output of the flexible member sensor. The seat belt tension may thus be continuously maintained at a desired level.

Abstract: An overhead airbag that may be used to protect and restrain the movement of a vehicle occupant is disclosed. The overhead airbag includes a cushion portion having a front panel, a first side panel, and a second side panel. A throat is also added to the cushion portion. The throat is positioned above the cushion portion. A patch is also added to airbag. The patch is attached to the cushion portion and is constructed such that when the airbag is in the inflated configuration, the airbag retains a depression between the cushion portion and the throat. More specifically, the patch is constructed such that when the airbag is in the inflated configuration, the airbag retains a depression between the front panel and the throat. A second patch that is attached to the throat and the second side panel may also be added.

Abstract: A turning loop cover is disclosed that is configured to slidably engage a turning loop and a fastener of a seatbelt system. The turning loop cover is primarily formed of a housing that has an internal volume and a first surface wherein a plurality of ribs extend from the first surface into the internal volume. The ribs are configured to attenuate a force acting upon the first surface of the housing.

Abstract: A vehicle impact sensing system for detecting impact events to a vehicle, and allowing deployment decisions of passive restraint devices based on information gathered and relayed regarding such impact events. The sensing system includes one or more sensor elements capable of directly detecting vehicle deformation occurring as a consequence of the impact event. The sensor elements generate an output that varies upon deformation of the element. The sensor elements are in communication with a restraints control module. Upon deformation of the sensor element, the control module receives impact signals from the sensor elements based upon the altered output, and discriminates between impact events that warrant deployment of a passive restraint, such as a side air bag, and those that do not. The control module utilizes information gathered from the sensor elements to make deployment decisions, such as which restraint to deploy and the appropriate degree of deployment.

Abstract: A sun visor assembly for a vehicle to be used in conjunction with an overhead airbag is disclosed. The sun visor assembly includes a visor panel, a pivot rod, and a mount for securing the sun visor assembly to the vehicle. The sun visor assembly also has a deflecting element for allowing the visor panel to be deflected out of the path of an inflating overhead airbag. The deflecting element could be a detachable catch mechanism that holds the visor panel in an operational position until the airbag deploys. The deflecting element could also be a spring loaded pivot or crease disposed within the body of the visor panel. The deflecting element could further be a tear seam or flexible fabric for channeling the trajectory of the overhead airbag.

Abstract: An occupant classification system for recognizing the type of occupant of a motor vehicle seat especially for use in controlling an inflatable restraint system. The classification system utilizes a number of on-off electrical switches arranged in a pattern on a seat cushion mat. Signals from the switches may be processed in a variety of manners to characterize the occupant.

Abstract: A load management system and method for controlling the activation sequence and times of activation of motor vehicle occupant restraints when a high g event, such as a crash, occurs. The system includes a microprocessor that processes inputs from a number of devices including seat weight sensor, an occupant spatial position detector, a buckle status detector, a belt sensor. The microprocessor is driven by a load management procedure that includes a high g event routine that controls the activation sequence of restraints so that the automatic locking restraint is first activated, followed by the pre-tensioner and then by the air bag. The load management procedure also includes an enable/disable procedure that controls the enabling and disabling of the restraints according to a number of variables including occupant weight, seat buckle status and belt extension status.

Abstract: A novel cover for a safety restraint device is disclosed. The cover is well-adapted for use in vehicles with modular airbag components. The novel cover configuration of the present invention effectively hides any evidence of the seam through which the airbag deploys, thereby improving the appearance and tamper-resistance of the airbag. The cover includes a seam with a nonlinear portion that impedes folding or bending of the outer layer in conformance with the seam. The nonlinear portion of the seam may include bends and linear segments in a variety of shapes and sizes, in homogeneous or heterogeneous arrangements, as dictated by the design parameters of the airbag and the manufacturing processes used to make the cover. The cover module of the present invention may be used with an outer layer of material designed to conceal the seam. With such a configuration, the nonlinear portion of the seam may keep the outer layer from form fitting to the seam so that no visible indentation over the seam will be shown.

Abstract: An enhanced overhead airbag assembly is provided. The overhead airbag assembly has an airbag module designed to be attached to the roof of a vehicle, rearward of the header. The airbag module is concealed from vehicle occupants via a headliner assembly that includes a headliner, header trim, central console, and sun visors. The header trim covers at least a portion of the header and overlaps the forward edge of the headliner on the passenger's side. The passenger's side headliner is shaped to form a deployment door to permit emergence of the inflating airbag cushion. The headliner is tethered to the roof via a frangible fastener so that the headliner does not interfere with inflation or strike the occupant.

Abstract: An inflation system and method of operation are provided which utilize or employ the magnetic characteristics of certain gases to selectively alter or change one or more inflation characteristic of the inflation output provided thereby or resulting therefrom. An inflation system for providing a supply of inflation medium to an inflatable restraint element includes an inflator device having a first chamber having contents including a quantity of at least one gaseous material having magnetic characteristics. The inflation system also includes a magnetic field inductor in magnetic field change inducing communication with at least a portion of the first chamber contents quantity of the at least one gaseous material having magnetic characteristics, wherein activation of the magnetic field inductor effects a change in at least one inflation characteristic of the inflator device, e.g., rise rate, gas mass flow rate and pressure output, produced or generated by the inflator.

Abstract: A linear actuator having a low profile and a long stroke is provided. The actuator includes a housing integrally connected to a telescoping piston. The piston may be extended by a fluid such as inflation gas provided by an inflation gas generator in fluid communication with the piston. The piston extends rapidly through a one-shot stroke. The extending piston converts energy in the fluid into motion for performing linear work. The linear actuator may be formed from a single piece of parent material through stamping processes including deep draw stamping. Alternatively, other metal forming processes may be used to form the linear actuator.

Abstract: A low density slurry bridge mix for use in an inflatable restraint system is provided. The low density slurry bridge mix includes zirconium metal, a thermal conductivity enhancer such as aluminum metal, potassium perchlorate oxidant, and a binder material and has a dry density of about 45 to about 65 percent of theoretical density. The low density slurry bridge mix may be used in an initiator including an unground header attached to a raised bridgewire wherein the low density slurry bridge mix surrounds and adheres to the bridgewire.

Abstract: A detachable three point seat belt assembly is provided. The seat belt assembly may have a belt extending downward along a seat from a retractor. In an anchored configuration, the distal end of the belt is attached to a static attachment feature by an interlocking buckle. A movable attachment feature coupled to the belt is engaged within a static buckle to buckle a vehicle occupant into the seat. In a free configuration, the interlocking buckle is disengaged from the static attachment feature so that the belt can be retracted along the seat. The interlocking buckle contains a latching lever and a pair of ejectors that operate in such a manner that insertion of the movable attachment feature enables withdrawal of the static attachment feature, and vice versa.

Abstract: A vehicle occupant restraint module includes an inflatable curtain having a first edge and a second edge. The inflatable curtain can be positioned in a folded state. A covering may partially enclose the inflatable curtain when it is in a folded state. A plurality of first attachment members are spaced along and extend from the first edge of the curtain. The covering is configured with slots to allow the first attachment members to extend through the covering. At least one and preferably multiple second attachment members secured to an out-board side of the covering. The first attachment members are positioned to secure a first portion of the module to a vehicle interior. The second attachment members are positioned to secure a second portion of the module to a vehicle interior below the first portion.

Abstract: An energy absorber for protecting the occupants of a vehicle. The energy absorber includes an interior portion and a first contact surface at least partially surrounding the interior portion. The first contact surface is attachable to a structural member of the vehicle. The energy absorber also includes at least one hollow cavity extending through the interior portion in a direction substantially parallel to the first contact surface. During a vehicle collision, the first contact surface absorbs energy from occupant impact with an interior trim piece by deforming into the hollow cavity.

Abstract: An integrated loadcell system, having a loadcell body having a leg connected to a spanning member, the leg having a transducer mounted thereto and a housing coupled to the loadcell body forming a wheatstone bridge circuit with the transducer; where an output of the wheatstone bridge circuit is indicative of a load experienced by the loadcell body.