INFLATABLE BOLSTER
An inflatable bolster for use in a passenger compartment of a vehicle is provided having a hollow body, an inflator and an attachment mechanism for attaching the hollow body to the vehicle's mating surface. The attachment mechanism includes a base retained within a molded cavity within the hollow body, and a fastener projection extending outward from both the base and the hollow body. Another attachment mechanism is provided including a dovetail portion which extends outward from the hollow body and engages a slot in the mating surface.
The present invention relates generally to the field of safety devices for vehicles. More particularly, it concerns an inflatable bolster for use in the passenger compartment of a vehicle.
BACKGROUND OF THE INVENTIONBolsters and the like are known in the art. A conventional bolster is mounted within a passenger compartment and includes a hollow body and an inflator for injecting a pressurized fluid into the hollow body. In order to reduce the potential for injuries caused during an impact event or the like, the inflator is activated upon detection of such an event and the bolster is inflated.
For example, the impact event may be a front, rear or side impact, a rollover, or any other event which is likely to cause a rapid change in the vehicle's momentum and thereby cause the occupant to strike some portion of the vehicle's passenger compartment. The fluid released by the inflator into the hollow body serves to inflate the bolster, bringing its outer surface closer to an occupant. By decreasing the distance between the occupant and its outer surface, the bolster can absorb more of the occupant's momentum over a longer period of time, thereby lessening the force experienced.
Bolsters may be provided as part of an instrument panel, a door panel, roof panel, a head rest, or other interior portion of the vehicle.
Known in the art are the following patent and patent applications which disclose inflatable bolsters and the like: US 2007/0108747; U.S. Pat. No. 6,032,978; U.S. Pat. No. 6,203,057; U.S. Pat. No. 6,305,710; U.S. Pat. No. 6,517,103; U.S. Pat. No. 6,578,867; U.S. Pat. No. 6,619,689; U.S. Pat. No. 6,758,493; U.S. Pat. No. 6,848,715; U.S. Pat. No. 6,976,706; U.S. Pat. No. 7,350,852; and WO 2006/132990.
Also known are the problems which arise when mounting such bolsters to the vehicle's interior, which is typically difficult to access. Moreover, it has been found that the reaction forces generated during inflation of the bolster can be violent enough to break the bolster free from its mounting within the vehicle, thereby significantly reducing its efficacy.
As such, it would be advantageous to provide an inflatable bolster which may be more conveniently installed. It would also be advantageous to provide an inflatable bolster which is mounted to vehicle in a robust and reliable way.
In addition, it is also known that conventional bolsters are often attached to the vehicle interior by bolts which are passed from inside the hollow body in order to connect with a complementary component such as a nut or a clip. It will be appreciated that this requires accessing the inside of the hollow body and drilling holes therein. However, such opening and/or drilling of the hollow body can weaken the hollow body and/or leave debris therein. In addition, it is known that significant pull-out forces are generated at the mounting points during inflation of a bolster. Mounting points with a conventional bonding structure, such as a simple bolt, may be insufficient to retain the bolster and the expanding vessel tear loose.
It would therefore be advantageous to provide an inflatable bolster which could be attached to the vehicle interior in a more robust way, without requiring an opening or drilling of the bolster.
SUMMARY OF THE INVENTIONIt is an object of the present invention to provide an inflatable bolster for use in a passenger compartment of a vehicle that satisfies at least one of the above-mentioned needs.
In accordance with an aspect of the present invention, that object is achieved with an inflatable bolster comprising a hollow body with a first wall devised to face a mating surface of the vehicle, the first wall being provided with a molded cavity, a second wall opposite the first wall and devised to face the passenger compartment, and an air chamber formed between the first and second walls. The bolster also comprises an inflator for injecting a pressurized fluid into the air chamber and thereby inflating the hollow body, the inflator being mounted to the hollow body, and an attachment mechanism for attaching the hollow body to the mating surface. The attachment mechanism includes a base retained within the molded cavity, and a fastener projection extending outward from the base and the first wall, the fastener projection devised to engage a complementary element on the mating surface and attach the inflatable bolster thereto.
Preferably, the molded cavity is formed around the base during molding of the hollow body, thereby encapsulating the base in the first wall. Alternatively, the base portion may include a male dovetail portion and the molded cavity includes a corresponding female dovetail portion having a side opening for allowing insertion of the male dovetail portion therein.
In accordance with another aspect of the present invention, the above mentioned object is achieved with an inflatable bolster comprising a hollow body with a first wall devised to face a mating surface of the vehicle, a second wall opposite the first wall and devised to face the passenger compartment, and an air chamber formed between the first and second walls. The bolster also comprises an inflator for injecting a pressurized fluid into the air chamber and thereby inflating the hollow body, the inflator being mounted to the hollow body, and an attachment means for attaching the hollow body to the mating surface, the attachment means includes a dovetail portion extending outward from the first wall, the dovetail portion devised to engage a slot on the mating surface and attach the inflatable bolster thereto.
Preferably, the mating surface includes a reaction plate for strengthening the inflatable bolster, the complementary element includes a slot, the slot having a side opening for allowing insertion of the dovetail portion therein; wherein the engagement of the dovetail portion and the slot retains the reaction plate to the inner wall.
As can be appreciated, an inflatable bolster according to either of the above-mentioned aspects may advantageously facilitate installation and/or may be attached without requiring an opening or drilling of the bolster.
Further aspects and advantages of the present invention will be better understood upon reading of preferred embodiments thereof with respect to the appended drawings.
While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the present description and appended claims.
DESCRIPTION OF PREFERRED EMBODIMENTSIn the following description, similar features in the drawings have been given similar reference numerals and in order to lighten the figures, some elements are not referred to in some figures if they were already identified in a preceding figure.
With reference to
The bolster 10 comprises a hollow body 12, an inflator 14 mounted thereto, and attachment means 16 for mounting the hollow body 12 to a mating surface within the vehicle. It will be appreciated that the expression mating surface should not be considered in a limiting manner, but rather should be considered to include all manner of structures, such as brackets and the like, to which the bolster 10 may be similarly mounted.
With additional reference to
The hollow body 12 is preferably molded from a suitable plastic material. More preferably, the hollow body 12 is made by extrusion blow molding, which is known in the art and will not be discussed further herein. The hollow body 12 comprises a first wall 18 and a second wall 20 which is opposite the first wall 18. An air chamber 22 is formed between the two opposite walls 18 and 20. When installed, the first wall 18 engages the vehicle's mating surface, and is therefore hidden from view, while the second faces the passenger compartment and any driver, passengers or otherwise therein.
The inflator 14, as is known in the art, is typically provided as a cartridge, although it will be appreciated that various other types of inflators are within the scope of the present embodiment. The inflator 14 is in fluid communication with the air chamber 22 and able to inject a pressurized fluid, typically a gas, therewithin. When installed, the inflator 14 is linked to various vehicle sensors which detect impact events and the like and are operable to activate the inflator 14 accordingly.
The first wall 18 is provided with a plurality of pleats 24, sometimes referred to as ribs, which surround the inflator 14 and the attachment means 16 concentrically. As is known in the art, these pleats 24 permit the bolster 10 to expand outward from the vehicle's mating surface and into the passenger compartment when inflated.
The attachment means 16, which can also be called an insert, comprises a base 26 and a fastener projection 28 which extends outwards therefrom. The first wall 18 comprises a molded cavity 30 which is formed as the hollow body 10 is molded and serves to receive and retain the base 26. The base 26 preferably has a flat shape which, when received within the molded cavity 30 extends in a direction substantially parallel to the first wall 18.
In accordance with the embodiment illustrated in
Also in accordance with the embodiment illustrated in
The base 26 can be injection molded around the threaded stud 28. In order to increase the strength of its encapsulation, the base 26 preferably has a disk-like shape and comprises a series of radial alternating ridges 32, as illustrated, which provide a greater surface area for contact with the material of the first wall 18 and further provide mechanical means for preventing the attachment means 16 from spinning within the molded cavity 30. In addition, the base 26 is preferably formed from a material which is compatible with the first wall 18. Specifically, it is preferable that the materials of the base 26 and the first wall 18 have similar surface energies in order to promote polymer bonding therebetween. Examples of such compatible materials include, but are in no way limited to, polyolefins with similar surface energies such as thermoplastic polyolefin (TPO), polypropylene or polyethylene-polypropylene copolymers. Preferably, the bolster 10 bonds a TPO to a TPO
With reference to
With reference to
With reference to
In use, a first snap 34 allows the vehicle assembler to attach the bolster 10 to the mating surface using a low force. During deployment of the bolster, the expansion forces will generate a higher force pushing the clip 28 further into the corresponding component which causes the clip 28 to engage the second snap 36. Once engaged, the second snap 36 requires significantly higher extraction force and as a result is able to remain installed when experiencing high pull out forces during deployment.
With reference to
With reference to
The molded cavity 30 and the female dovetail portion 42 are formed during molding of the hollow body 12. Preferably, the molded cavity 30 further comprises an alignment area 48 which is at least as wide as the male dovetail portion 44 and provided adjacent the side opening 46. During assembly, the vehicle assembler can place the male dovetail portion 44 within the alignment area 48 before sliding it into the female dovetail portion 42. Once inserted, the corresponding angled surfaces of the female and male dovetail portions 42 and 44 will prevent the attachment means 16 from being pulled out. In addition, molded cavity 30 preferably comprises a snap feature 50 which allows sliding of the male dovetail portion 44 into the female dovetail portion 42, but prevents it from sliding outward therefrom and back into the alignment area 48.
In this embodiment, the fastener projection 28 is similar to that of the first embodiment.
With reference to
With reference to
In use, the spring bolt 16 is twisted through a reaction plate 56 (
Preferably, the spring bolt is made from a resilient material which can stretch during deployment of the bolster 10 in order to reduce the local force concentrations thereon while maintaining the bolster 10 in its desired position. It will be appreciated that the reduced internal bolster forces will increase the bolster operating window.
With reference to
The dovetail portion 58 is devised to engage a corresponding slot 60 on the reaction plate 56, although it will be appreciated that such a slot 60 would similarly be used in a variety of other types of mating surfaces. The slot comprises a side opening 62 for allowing the dovetail portion 58 to be slid therein. Preferably, the slot 60 comprises an alignment area 64 adjacent the side opening 62. During assembly, the alignment area 64 can be placed around the dovetail portion 58, or vice-versa, before sliding the dovetail portion into the slot 60.
The dovetail portion 58 provides strength required to hold the bolster in position under operating conditions and allows for installation without access to the rear side of the bolster 10. It will be appreciated that the dovetail portion 58 may be of various configurations known as being male or female.
Although the present invention has been explained hereinabove by way of a preferred embodiment thereof, it should be understood that the invention is not limited to this precise embodiment and that various changes and modifications may be effected therein without departing from the scope of the invention.
Claims
1. An inflatable bolster for use in a passenger compartment of a vehicle, the inflatable bolster comprising:
- a) a hollow body comprising: i. a first wall devised to face a mating surface of the vehicle, the first wall being provided with a molded cavity; ii. a second wall opposite the first wall and devised to face the passenger compartment; and iii. an air chamber formed between the first and second walls;
- b) an inflator for injecting a pressurized fluid into the air chamber and thereby inflating the hollow body, the inflator being mounted to the hollow body; and
- c) attachment means for attaching the hollow body to the mating surface, the attachment means comprising: i. a base retained within the molded cavity; and ii. a fastener projection extending from the base and outward from the first wall, the fastener projection devised to engage a complementary element on the mating surface and attach the inflatable bolster thereto.
2. The inflatable bolster of claim 1, wherein the molded cavity is formed around the base during molding of the hollow body, thereby encapsulating the base in the first wall.
3. The inflatable bolster of claim 2, wherein the base and the hollow body are formed of compatible materials having compatible surface energies which enables polymer bonding therebetween.
4. The inflatable bolster of claim 2, wherein the base has a disk-like shape and comprises a series of radial alternating ridges.
5. The inflatable bolster of claim 2, wherein the fastener projection is a threaded stud.
6. The inflatable bolster of claim 2, wherein the fastener projection is a clip.
7. The inflatable bolster of claim 6, wherein the fastener projection is a duel level snap clip.
8. The inflatable bolster of claim 1, wherein the first wall comprises angled sections.
9. The inflatable bolster of claim 1, wherein the base portion comprises a male dovetail portion and the molded cavity comprises a corresponding female dovetail portion having a side opening for allowing insertion of the male dovetail portion therein.
10. The inflatable bolster of claim 9, wherein the molded cavity further comprises a clip proximate the opening for retaining the base within the molded cavity after insertion.
11. The inflatable bolster of claim 9, wherein the fastener projection is a threaded stud.
12. The inflatable bolster of claim 9, wherein the fastener projection is a clip.
13. The inflatable bolster of claim 12, wherein the fastener projection is a duel level snap clip.
14. An inflatable bolster for use in a passenger compartment of a vehicle, the inflatable bolster comprising:
- a) a hollow body comprising: i. an first wall devised to face a mating surface of the vehicle; ii. a second wall opposite the first wall and devised to face the passenger compartment; and iii. an air chamber formed between the first and second walls;
- b) an inflator for injecting a pressurized fluid into the air chamber and thereby inflating the hollow body, the inflator being mounted to the hollow body; and
- c) attachment means for attaching the hollow body to the mating surface, the attachment means comprising: i. a dovetail portion extending outward from the first wall, the dovetail portion devised to engage a slot on the mating surface and attach the inflatable bolster thereto.
15. The inflatable bolster of claim 14, wherein the mating surface comprises a reaction plate for strengthening the inflatable bolster, the complementary element comprises a slot, the slot having a side opening for allowing insertion of the dovetail portion therein; wherein the engagement of the dovetail portion and the slot retains the reaction plate to the inner wall.
Type: Application
Filed: Apr 14, 2009
Publication Date: May 12, 2011
Inventors: Michael James Best (Newmarket), Raj S. Roychoudhury (Bloomfield Hills, MI), Rimas Ciplijauskas (Etobicoke), Babak Fana (Mississauga)
Application Number: 12/937,096
International Classification: B60R 21/20 (20110101); B60R 21/217 (20110101);