Abstract: An airbag tether retainer is disclosed that is of minimal size to accommodate vehicle safety and styling requirements and yields to conform to contours of a vehicle pillar. The tether retainer is interchangeable with left or right vehicle pillars thus reducing fabrication costs. The tether retainer imposes minimal stress on a worker attaching the retainer. In certain embodiments, the tether retainer includes a body and one or more tabs and corresponding tab locks which extend from the body. An airbag tether is positioned on the body and each tab is looped around the tether and secured to the body by a corresponding tab lock. The body may then be secured to a vehicle pillar.

Abstract: An inflator such as for supplying inflation fluid to an inflatable vehicle occupant restraint is provided. Such an inflator includes an elongated hollow tubular member containing an elongated supply of pyrotechnic gas generant material reactable to produce a supply of gas. The tubular member has a length to diameter ratio greater than 20 and includes a plurality of longitudinally-spaced apart gas exit orifices wherethrough at least a portion of the supply of gas provided by reaction of the pyrotechnic gas generant material can be expelled from the tubular member. Also provided are associated or related inflation assemblies and methods for inflatable device inflation.

Abstract: Gas generant filter assemblies and related combinations, including airbag inflator devices, are provided which assemblies include a tubular wall portion with a sleeve member and a central opening adapted to at least in part contain a supply of gas generant material reactable to produce reaction products including a quantity of gas. The assemblies also include a closure such as disposed within the central opening at the second end of the central opening. The sleeve member is shapeable to form a plurality of retention tabs effective to secure the closure within the central opening at the second end.

Abstract: An airbag cushion for protecting an occupant of a vehicle from an impact is presented. The airbag cushion has an inflatable region which inflates upon the reception of an inflation gas from an inflator. The airbag cushion is secured to a housing by a retaining member. The retaining member is configured to secure an attachment region of the airbag cushion to the housing by the use of fasteners which create a clamping force. The clamping force is highest adjacent the fasteners and is lowest at positions between the fasteners. Thus, a high clamp region is created adjacent the fasteners and a low clamp region is created at positions distant from the fasteners. As the airbag cushion is inflated, a load force puts tension on the attachment region of the airbag cushion potentially ripping the airbag cushion out from the low clamp regions. A load controlling cutout is positioned within the attachment region and between the fasteners.

Abstract: The present invention relates to a gas guide for distributing inflation gas into a cushion for an airbag module such as an inflatable curtain module. The gas guide has a first end connected to an inflator, a second end disposed within the cushion, and an intermediate portion between the first and second ends. The second end has a second opening and the intermediate portion has an intermediate opening. The intermediate portion has a small radius bend proximate the intermediate opening such that first and second portions of the inflation gas leave the second opening and the intermediate opening, respectively, to inflate different portions of the cushion. The second end may be constricted such that back pressure in the intermediate portion urges the second portion through the intermediate opening. In addition or in the alternative, a deflector may be used to channel the second portion through the intermediate opening.

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 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: 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: 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 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: 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: 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 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: 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: 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 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: 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: 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.