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 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 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: 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: 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: 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: 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 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: A severing apparatus for use with a battery cable is provided. The severing apparatus includes a housing that holds an initiator and a severing element. The battery cable is located through a lateral bore formed in the housing. The severing element is disposed on one side of the battery cable. A deformable blocker can be disposed on the opposite side of the battery cable. When it is desired to sever the battery cable and thereby discontinue the supplying of electrical power by the battery, such as when a predetermined vehicle collision occurs, the initiator is triggered and causes the severing element to move. Movement of the severing element removes a severed battery cable segment. Movement of the severing element and the severed battery cable segment is stopped using the blocker when present. The blocker can be part of a shell that surrounds the housing. Alternatively, the blocker can be held in the housing.

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.

Abstract: The present invention involves a method of actuating a deployment of a vehicle airbag during an impact event of a vehicle. The method includes providing a vehicle impact sensor having a plurality of elements, wherein each element is adapted to generate an impact sensor signal having a sensor signal value representing a level of impact. The method further comprising receiving an impact sensor signal from each element during the impact event of the vehicle and summing the sensor signal values of the impact sensor signals to define an aggregate sensor signal value. The method further includes determining a number of impact sensor signals having respective sensor signal values greater than an active element threshold value to define a number of active elements and determining a threshold aggregate sensor signal value based on the number of active elements.

Abstract: A bumper assembly having a movable bumper is disclosed. A crash sensor is attached to the movable bumper. A linkage is provided to attach the movable bumper to a motor vehicle. When the movable bumper is attached to the motor vehicle, the linkage permits the movable bumper to be moved from a first position to a second position that is horizontally displaced from the first position in a direction away from the motor vehicle. Extending the bumper in this manner allows the crash sensor to provide early detection of a collision involving the motor vehicle.

Abstract: The invention provides a self-contained, compact inflatable airbag deployment guide comprising an inflatable bladder attached to an inflatable airbag module. The inflatable bladder inflates early in the deployment of the airbag, thus filling, bridging, or covering void space located near the airbag cushion. The airbag cushion is then able to deploy properly on its intended route through the headliner trim of the vehicle without being delayed, damaged, or caught.

Abstract: A dual flow inflator for airbags is disclosed, together with related manufacturing, installation, and deployment methods. The inflator includes a primary gas chamber with a first exit orifice and a secondary gas chamber in gaseous communication with the primary gas chamber. The inflator also includes a flow restrictor positioned between the gas chambers. In use, the inflator provides primary and secondary flows of gas from the exit orifice. The primary gas chamber may include multiple exit orifices in order to provide axial gas flows in opposite directions upon activation so that each gas flow neutralizes the thrust of the other. The exit orifices may comprise frangible structures such as burst discs, scored surfaces, and compression closures.

Abstract: Methods and apparatuses for gas generation via a water-supplying compound and a water-reactive fuel precursor.

Abstract: A pillar-mounted airbag module is disclosed. The frontal airbag module of the invention includes an airbag cushion configured to be deployed from a pillar of a vehicle and an airbag inflator coupled to the airbag cushion, the airbag inflator being suitable for attachment to a pillar of a vehicle. The frontal airbag module of the invention is configured to deploy the airbag cushion laterally along a windshield of the vehicle and then to subsequently inflate the airbag cushion toward the vehicle occupant.

Abstract: An inflatable curtain package that is made of an inflatable curtain wrapped around by a thin film is disclosed. The inflatable curtain has a number of mounting tabs that allows the inflatable curtain to be attached to a vehicle. The orientation of the thin film allows mounting tabs to extend out of a seam in thin film. The inflatable curtain package may be constructed by aligning a first edge of the thin film to a position near a location wherein the mounting tabs attach to the inflatable curtain. Next, the mounting tabs are positioned over the first edge of the thin film. Then a second edge of the thin film is positioned to overlap the first edge and the attachment location. The two overlapping edges cause the thin film to wrap around the inflatable curtain.

Abstract: A novel safety restraint system especially well suited to protect occupants of a vehicle from lateral impact is described. One or more cushion portions are provided and installed to inflate between an occupant and a lateral surface, such as a door or side window. The cushion portions may be connected to an air source or to each other through the use of sail portions and supply tubes, which may be attached to the cushion portions by chemical bonding, adhesive bonding, sewing, RF welding, or any other suitable method. The cushion portions may have an interior coating of a urethane based substance, mated to a similar substance coating the exterior of a supply tube or sail portion. The cushion portions may then be RF welded to the sail portion or supply tube without restricting gas flow into the cushion portions. The sail portions and supply tubes are preferably fabricated from a material different from that used to form the cushion portions, so as to reduce the cost and weight of the safety restraint system.

Abstract: A lighter, low-cost inflatable restraint module is disclosed. The inflatable restraint module may include an inflator positioned within a heat shield. The heat shield and inflator may be disposed within an inflatable cushion. A portion of the cushion containing the inflator and heat shield is situated within a chamber. The chamber may include an opening in the chamber and an extension that projects away from the opening. Attachment of a portion of the inflatable cushion to the extension keeps the portion of the cushion away from the opening of the chamber and, thus, away from potentially damaging heat generated by the inflator. Alternatively, the portion of the cushion may be kept away from the opening by attachment to a cover which is, in turn, attached to the extension. The inflator, heat shield, chamber, and cushion may be secured within an interior region of a canister.