Abstract: An inflatable cushion for a vehicle occupant restraint system includes a bag formed of flexible material and defining an internal cavity, and inflatable to a predetermined three-dimensional configuration. The bag is constructed of a plurality of panels of a durable, flexible material which are joined together to define a predetermined three-dimensional configuration such that at least a part of the bag will overlie an A pillar of a vehicle when the bag is in an inflated condition.

Abstract: An assembly and method are provided for the attachment of a protective cover to an airbag module assembly wherein the possibility of a portion of the folded airbag cushion extending over either of the sides of the reaction canister body and thus subject to being snagged or caught between the reaction canister body and the end plate upon attachment of the end plate(s) to the reaction canister body is avoided.

Abstract: An inflatable restraint airbag module for the protection of an occupant of a vehicle is provided wherein portions of a tethered airbag cushion are separately folded and stored within a module housing to provide a deployment process that can serve to minimize or avoid problems such as bag slap and improper positioning of the airbag cushion upon deployment.

Abstract: The invention provides a method and device for assembling an inflatable cushion with a reaction housing in an inflatable restraint system. A die is provided which includes at least one cavity extending through the die, and an elongate slot communicating with the interior of the cavity and disposed along the length thereof. The assembly is accomplished by aligning the die with the reaction housing to permit axial passage of a cushion insert, formed at the gas inlet opening of the inflatable cushion, through the die cavity into a mateable sleeve of the reaction housing.

Abstract: An inflatable airbag which provides for vehicle occupant restraint when inflated has a tether inside said airbag. One end of the tether is attached to the airbag wall at a point or line away from the mouth of the airbag and the opposite end of the tether is fastened to a canister by means of a retaining rod housed inside a hemmed loop at the end of the tether. The retaining rod inside the hemmed loop is retained in a slotted rail or channel on the canister. Stress in the tether is transmitted directly from the tether to the retaining rod and thence to the canister.

Abstract: An inflator for use in an airbag module assembly including a reaction canister having a stud-receiving opening in a front canister endplate and an inflator-receiving aperture in a rear canister endplate. The inflator includes an inflator housing and a mounting adapter, the inflator housing having a generally cylindrical sidewall, a front housing end with a mounting stud extending therefrom, and a rear housing end including an endwall and a boss, the boss extending rearwardly from the endwall. The mounting adapter includes an adapter end cap defining an opening. The adapter end cap is positioned adjacent the endwall of the inflator housing with the boss extending through the opening. The mounting adapter is secured to the housing by a mechanical interengagement between the adapter end cap and the rear housing end.

Abstract: A fold configuration of top mounted air bag cushions which tend to deploy high in a vehicle compartment and slap the face of an occupant uses several fold variations including a loop of fabric on top, folded side wing panels, a roll comprising a plurality of folds, and an upper pleat and a pleat producing tuck which inversely roll down the vehicle dashboard when an inflating fluid under pressure from an inflator flows into the cushion, which folds can only unfold in sequence one after another so that expansion of the cushion is stopped at a predetermined extended length which creates an initial gas-fill cavity that overpressurizes taking additional energy to unfurl the remaining cushion, which slows the deployment, with the side wing panels folded toward the bottom of the cushion so that the side wing panels, when inflated, deploy low into the occupant's lap.

Abstract: A passenger side air bag exhibits controlled deployment of a vertically elongated frontal surface prior to full inflation. The air bag includes a depending lobe extending downwardly from the inlet opening secured to an inflator module mounted in a dashboard. A portion of the front panel of the air bag is releasably secured, such as by breakaway stitching, to a portion of the rear of the depending lobe, below the inlet opening. Outward deployment of the air bag in an elongated column is prevented by the stitching, and a broad front surface develops early in the deployment and inflation process. The breakaway stitching releases part way through the deployment and inflation process, and the front surface then fills out to full inflation. Higher stitch density in the area of stitching which first releases contributes to controlled deployment.

Abstract: An improved fold configuration of top mounted air bag cushions which tend to deploy high in a vehicle compartment and tend also to deploy at great velocity at an occupant's head uses several fold variations including a folded bubble on top, tucks, a pleat and rolls which inversely roll down the vehicle dashboard when an inflating fluid under pressure flows into the cushion, which folds can only unfold in sequence one after another so that the cushion does not unfold faster than it can be filled with inflating fluid and deploys relatively slowly in a downward trajectory.