Abstract: The present invention provides a system and method for distributing inflation gases within an airbag cushion. Such a cushion may have one or more protection zones configured to inflate to protect vehicle occupants. An inflation channel maybe enclosed by one or more of the protection zones, and may be attached to a mounting surface within a protection zone. The inflation channel may be connected to an inflator, and may have a plurality of holes along its length, sized or spaced apart in a manner selected to provide a comparatively even flow rate of inflation gas to all parts of the cushion during inflation. Additionally, the inflation channel may have a gas outlet extension along which the holes are disposed; the gas outlet extension may have a tapered shape configured to collapse under external pressure to prevent backflow of inflation gases into the inflation channel.

Abstract: A system and method for enhancing the interchangeability, cost effectiveness, and protective capacity of side impact, inflatable curtains is disclosed. An inflatable curtain module may have multiple cushions attached together by a separately manufactured inflatable tension coupling. The tension coupling may be attached to the cushions prior to folding of the cushions by, for example, sewing one end of the tension coupling to each cushion. The tension coupling may also be attached to the cushions after the cushions have been folded. The cushions may each have one or more tabs positioned to extend inward toward the tension coupling; the tabs may protrude from the folded cushions so that the tension coupling can be attached to the tabs after the cushions have been folded.

Abstract: A system and method for reducing the profile of compacted seams in an inflatable curtain modules is disclosed. A cushion of an inflatable curtain module has interior seams configured to separate the cushion into chambers. The interior seams are angled with respect to the direction along which the cushion is compacted to ensure that each interior seam does not simply bunch up at a one single location along the length of the compacted cushion. Preferably, the interior seams are angled so that overlap does not occur along at least half the length of each interior seam. The angle may be further selected to ensure that no overlap occurs, or even that no two portions of any interior seams can interfere to create a combined bulge. The interior seams may be modestly angled, aggressively angled to form a nested configuration, or even angled perpendicular to the compaction direction.

Abstract: A system and method for enhancing the interchangeability, cost effectiveness, and protective capacity of side impact, inflatable curtains is disclosed. An inflatable curtain module may have multiple cushions attached together by a separately manufactured inflatable tension coupling. The tension coupling may be attached to the cushions prior to folding of the cushions by, for example, sewing one end of the tension coupling to each cushion. The tension coupling may also be attached to the cushions after the cushions have been folded. The cushions may each have one or more tabs positioned to extend inward toward the tension coupling; the tabs may protrude from the folded cushions so that the tension coupling can be attached to the tabs after the cushions have been folded.

Abstract: ABSTRACT OF THE INVENTION The present invention provides a system and method for distributing inflation gases within an airbag cushion. Such a cushion may have one or more protection zones configured to inflate to protect vehicle occupants. An inflation channel maybe enclosed by one or more of the protection zones, and may be attached to a mounting surface within a protection zone. The inflation channel may be connected to an inflator, and may have a plurality of holes along its length, sized or spaced apart in a manner selected to provide a comparatively even flow rate of inflation gas to all parts of the cushion during inflation. Additionally, the inflation channel may have a gas outlet extension along which the holes are disposed; the gas outlet extension may have a tapered shape configured to collapse under external pressure to prevent backflow of inflation gases into the inflation channel.

Abstract: A system and method for reducing the profile of compacted seams in an inflatable curtain modules is disclosed. A cushion of an inflatable curtain module has interior seams configured to separate the cushion into chambers. The interior seams are angled with respect to the direction along which the cushion is compacted to ensure that each interior seam does not simply bunch up at a one single location along the length of the compacted cushion. Preferably, the interior seams are angled so that overlap does not occur along at least half the length of each interior seam. The angle may be further selected to ensure that no overlap occurs, or even that no two portions of any interior seams can interfere to create a combined bulge. The interior seams may be modestly angled, aggressively angled to form a nested configuration, or even angled perpendicular to the compaction direction.

Abstract: An improved method for fabricating a filter for use in automotive air bag inflators which comprises forming a hollow cylindrical inner core or combustion screen of filter material and outer filter layers wound outward from the surface of the core so as to be maintained in cylindrical relation thereabout. This invention is specifically directed to an improved filter which does not include a perforated support tube and relies on only the interior combustion screen for support in the final wrapping of the remaining filter structure.

Abstract: An improved method for fabricating a filter for use in automotive air bag inflators which comprises forming a hollow cylindrical inner core or combustion screen of filter material and outer filter layers wound outward from the surface of the core so as to be maintained in cylindrical relation thereabout. This invention is specifically directed to an improved filter which does not include a perforated support tube and relies on only the interior combustion screen for support in the final wrapping of the remaining filter structure.

Abstract: An air bag cover attachment includes a housing formed by extrusion. The housing includes a section for receiving a gas generator, and a pair of spaced parallel side walls which define a storage area for the uninflated cushion. The free ends of the side walls include flanges which are notched to form a series of mounting tabs. The cover includes a depending skirt having slots which mate with the tabs. The strength of the extruded tabs permits the tabs and slots, with no other fastener, to secure the cover to the housing. The slots are oversized to permit the cover to float with respect to the housing. The cover also includes a set of placement tabs extending from the skirt. The placement tabs secure the cover to the dashboard in the proper position. The oversized slots and separate placement tabs ensure that the decorative cover is mounted on the dashboard in the proper position by absorbing tolerance buildup in the housing and housing position.

Abstract: An inflatable air bag module for motor vehicles includes a housing for containing an air bag in deflated condition and an inflator assembly for providing gas to inflate the air bag when activated. The housing includes a first compartment holding the deflated air bag and having an exposed outer cover on one side formed with a fracture line defining an edge of a door. The door is adapted to pivot open along a hinged area when the cover is fractured by pressure from the inflating air bag as it expands out of the compartment. The housing also includes a second compartment holding the inflator assembly and a generally flat divider panel is provided between the first and second compartments with openings therein for permitting gas from the inflator assembly to rapidly inflate the air bag.

Abstract: A break-away retaining flap for containing a deflated, folded-up airbag in a rigid housing of an airbag module while a pivotable cover is attached with fasteners to close an open end of the housing comprises a sheet of thin flexible woven fabric material having a first portion designed for attachment to the housing on a line spaced away from the open end and a second portion adapted to be secured onto a row of fasteners adjacent the open end of the housing while the cover is attached. The retaining flap holds the folded-up airbag in place in the housing during the assembly process and prevents crimping, binding or damage when the cover is installed at final assembly. The retaining flap has a weakened portion intermediately between the first and second attached portions defining a tear-away line adapted to facilitate break-away of the retaining flap into at least two parts when the airbag is inflated without impeding the rapid inflation of the airbag during deployment.

Abstract: An enclosure, adapted to hold an auto ignition material in a gas generator that employs solid fuel gas generant material to effect inflation of a protective bag to cushion a passenger from impact with the structure of a vehicle in the event of a crash, is provided.