Abstract: An inflatable rigid knee airbag system for assisting in positioning and decelerating a vehicle occupant is disclosed. The system may include a front and a rear rigid panel, which may be made from sheet metal. The front and rear rigid panels define at least a portion of an inflatable chamber. The inflatable chamber is in fluid communication with an inflator that injects inflatable gas into the inflatable chamber when accident conditions exist. A support core positioned between the front and rear panels dampens vibrations of the front and rear panels and minimizes unsightly denting of the front panel when the inflatable rigid knee airbag system is in a pre-deployment state. The support core may be made from foam.

Abstract: An airbag mounting system for orienting an inflator, a retaining ring, an airbag cushion and a housing module of an airbag module assembly. The assembly includes an annular retaining ring having a plurality of first fastener openings circumferentially spaced about the ring. At least two of the plurality of first fastener openings being spaced from each other along the ring circumference by a first angle. At least one of the plurality of first fastener openings is offset from at least one of the at least two first fastener openings by a second angle different from the first angle. A module housing includes a plurality of second fastener openings circumferentially spaced about a central inlet opening. At least two of the second fastener openings are spaced from each other along the circumference by a third angle. At least one of the second fastener openings is offset from at least one of the at least two second openings by a fourth angle which is different from the third angle.

Abstract: A breakaway latch plate for use with the seat belt system is disclosed. The breakaway latch plate includes a latch plate body that may be selectively secured to a buckle. An orifice may be disposed within the latch plate body. Seat belt webbing passes through the orifice. A locking mechanism is coupled to the latch plate body. In a locked state, the locking mechanism prevents movement of the seat belt webbing relative to the latch plate body. When a predetermined load is applied to the seat belt webbing, the locking mechanism changes to an unlocked state, in which the seat belt webbing may move relative to the latch plate body.

Abstract: Pyrotechnic compositions such as used in initiator devices and corresponding initiator devices having a low firing energy are provided. The pyrotechnic composition includes a mixture containing a fuel component which includes a quantity of at least one Iron Blue Pigment and an oxidizer component which includes at least one oxidizer effective, upon reaction initiation with at least a portion of the quantity of the at least one Iron Blue Pigment, to produce gaseous reaction products. The pyrotechnic composition may additionally include a burn rate enhancing additive such as zirconium metal powder.

Abstract: A tether assembly attachable to an inflatable cushion airbag module is disclosed that is usable in vehicles including trucks, SUVs, and other vehicles with abrupt rear surfaces. The tether assembly does not require that the rear tether be extended back from the rear edge of the airbag. The tether assembly may be used in connection with an inflatable cushion airbag secured to the front portion of the vehicle using a standard front tether system. The tether assembly is attached via a sliding mechanism to a rear tether used to secure an inflatable cushion module airbag to an anchoring point within the vehicle. The sliding mechanism is also connected to a retractor, preferably through a flexible connector made of the webbing material used in seat belts. The tether assembly is configured so that when the inflatable cushion airbag deploys during an accident, the retractor supplies rearward tension on the airbag by causing the sliding mechanism to move along the path of the tether.

Abstract: An inflator is provided that can reduce the occurrence of virtual and masked leaks in inflator testing. The inflator may have an outer wall surrounding a main internal compartment containing compressed inflation gases. Additionally, the inflator may have a pyrotechnic assembly containing a generant, or pyrotechnic material, and an initiator configured to ignite the pyrotechnic material upon receipt of an electric signal from a vehicle's electrical system. The initiator may be separated from the pyrotechnic material, and from the compressed gases, by a pressure dome that effectively creates a cavity around the initiator. The initiator may be accessible to outside contact through an opening in the outer wall. An insert may be positioned around the initiator to control flows of gas leaving the cavity through the opening.

Abstract: An air-bag arrangement for use in a motor vehicle, secured to the vehicle at points along a non-linear line above an opening in the vehicle. The arrangement incorporates an inflatable element, connectors to secure an edge part of the inflatable element to the vehicle, and an inflator to inflate the inflatable element. The invention also incorporates a tether arrangement including a first and second tether. The first tether has opposed ends secured to the inflatable element. The second tether has a first end associated with the first tether intermediate its ends and a second end secured to the motor vehicle. When the inflatable element is inflated, a lower region of the inflatable element and the tethers extend between two opposed ends of the non-linear line and are substantially taut.

Abstract: An attachment assembly for attaching a cushion member for an airbag apparatus to a vehicle surface is disclosed. The attachment assembly is particularly useful for attaching curtain type cushion members, as for a side impact airbag system. The attachment assembly may include a protrusion with a rod and a knob larger than the rod. A compressible spring washer is affixed to the rod. A hole formed in a mounting portion of the cushion member is then fitted around the rod, outside the washer. A cap is affixed to the rod to keep the cushion member in place. The protrusion, with the attached cushion member, may then be affixed to the vehicle surface through the use of a keyhole formed in the vehicle surface. The knob is pushed longitudinally into a larger, clearance portion of the keyhole, such that the spring washer is compressed. Then, the protrusion is moved transversely into an engaged configuration, in which the knob and the spring washer engage the interference portion.

Abstract: An inflatable seat belt system providing protection to its inflatable members is disclosed. The system may include inflatable shoulder belts and lap belts, which may or may not be inflatable. Each inflatable belt includes seat belt webbing having an interior cavity in which an inflatable member is placed. The seat belt webbing also includes a frangible seam that bursts upon inflation of the inflatable member. The inflatable seat belt system may also include one or more anti-submarining (crotch) belts that prevent an occupant from slipping underneath the protection of the lap and shoulder belts.

Abstract: A novel vehicle occupant restraining module is described. The retraining module includes an inflatable cushion having an inner surface and an outer surface. The inflatable cushion is capable of receiving inflation fluid from an inflation fluid source. A retaining collar is positioned adjacent a mouth of the cushion and about the inflation fluid source to retain the inflatable cushion in communication with the inflation fluid source. The retaining collar includes a flange that flares elliptically outward from the inflation fluid source. The retaining collar also includes an extension tab for preventing the cushion from contacting the inflation fluid source after inflation.

Abstract: An air-bag arrangement for use in a motor vehicle is often secured to the vehicle at points extending along a non-linear line located above an opening in the vehicle. The arrangement incorporates an inflatable element, connectors to secure an edge part of the inflatable element to the vehicle, and an inflator to inflate the inflatable element. The air-bag arrangement also incorporates a tether arrangement including a tether of elongated form having first end secured to the inflatable element adjacent the connectors and the second end secured to the vehicle. The tether movably passes through a guide located adjacent one end and the lower region of the inflatable element. Advantageously, when the inflatable element is inflated, a lower region of the inflatable element is taut and, together with the tether, extends between the two opposed ends of the non-linear line.

Abstract: The present invention provides a system and method for tethering that may be used to keep a cushion properly positioned for side impact protection, particularly in vehicles in which space rearward of the cushion is limited. A tether attachment assembly according to the invention may include a tether attached to the cushion and to an anchoring point within the vehicle. An intermediate portion of the tether may pass within a tether restraint assembly that includes a tether restraint member attached to a vehicle surface. The tether restraint member may be a flexible strap, rigid bar, or the like. When the cushion deploys, the tether slides along the tether restraint member such that the tension exerted by the tether on the cushion is in the longitudinal direction.

Abstract: Gas generant compositions which include at least one transition metal complex of ethylenediamine 5,5′-bitetrazole are provided to produce or results in compositions having relatively high burn rates. Also provided are corresponding or associated gas generating devices and inflatable vehicle occupant safety restraint systems and methods of gas generation.

Abstract: A binder matrix suitable for use in a gas generant composition, a gas generant composition including the binder matrix, and a related method of igniting such a gas generant composition are provided. The binder matrix includes a non-energetic binder material and dimethyl malonate non-energetic plasticizer and has a softening temperature above at least about 125° C. A gas generant composition including the binder matrix includes a non-energetic binder material such as cellulose acetate, dimethyl malonate non-energetic plasticizer, a fuel such as a nitramine fuel such as RDX, HMX or a combination thereof, and a stabilizer such as N-methyl-p-nitroaniline.

Abstract: A load distribution panel retention apparatus which effectively secures a knee bolster airbag to a load distribution panel. The apparatus includes a flat, rectangular piece of textile material attached to a knee bolster airbag to form a panel retainer which is open on both ends. A load distribution panel, also called a knee bolster panel, is secured to the airbag by positioning the load distribution panel between the panel retainer and the airbag. The apparatus includes a housing secured to the instrument panel or to a firewall of a vehicle. The conventional inflatable knee airbag is stored within the housing and in communication with an inflator. The inflator is stored within the housing and inflates the knee airbag in an accident situation. A trim cover panel is attached to the load distribution panel to provide a decorative covering of the airbag module.

Abstract: A microstrain sensor is provided for measuring deformation, and indirectly, other parameters such as acceleration, temperature, pressure, and force. Rather than providing several discreet resistance paths, the microstrain sensor utilizes input and output conductors connected to a single piece of film through which current travels to indicate resistance. The film provides superior resistance to external effects, such as temperature gradients, that decrease the accuracy of the sensor's readings. Such sensors may be easily adapted for use in situations in which opposing stresses are present, such as dually constrained members, by disposing separate or unitary film sections on opposite sides of a zero stress point, such as a central plane of a fixed-guided beam. Such sensors may be utilized in many different applications, including automotive safety systems.

Abstract: A non-inverting dual voltage regulation set point power supply for a restraint control module is disclosed that includes a main power source. A regulated voltage generation circuit connected with said main power source for generating a regulated output voltage having an upper set point and a lower set point. A buck switch connected to said main power source and said regulated voltage generation circuit for bucking the regulated output voltage generated by said regulated voltage generation circuit to said upper set point if said voltage supplied from said main power source is greater than said upper set point. A boost switch connected with said regulated voltage generation circuit for boosting the regulated output voltage generated by said regulated voltage generation circuit to said lower set point if said voltage supplied from said main power source is less than said lower set point.

Abstract: Gas generating compositions containing or including a sufficient quantity of a non-nitrate containing ammonia source whereby, upon reaction of the gas generating composition, NOx products are present in the product gas in a reduced amount as compared to reaction product gas resulting from reaction of the same composition without said quantity of non-nitrate containing ammonia source. Also disclosed are associated methods of reducing NOx products present in an effluent of a gas generating composition that upon combustion forms gas useful for inflating a vehicle occupant safety restraint device.

Abstract: Inflator device assemblies containing an expandable fluid effective to provide a gaseous inflation medium also advantageously employ or incorporate a pyrotechnic material such as to augment or enhance at least one fill characteristic of the gaseous inflation medium. The pyrotechnic material is provided on a selected non-gas generant surface within the inflator device. Suitable pyrotechnic compositions may include a binder additive effective to adhere the pyrotechnic composition to a surface within the inflator device.

Abstract: A seat sensor 10 including a pressure sensing mat 12, and several barbed members or tabs 14 which are integrally formed within sensing mat 12. Sensor 10 is adapted to be operatively installed on a conventional vehicle seat. In order to install sensor 10, several holes or cavities 20 are formed within the foam 22 of the seat in a conventional manner prior to assembly, and tabs 14 are forced into cavities 20. Once tabs 14 are inserted into cavities 20, barbed portions 18 “spring” outward against the sides of the cavities 20, thereby frictionally engaging and/or piercing the sides of the cavities 20 and securing seat sensor 10 to the seat.