Patent Application
20050134032
The present invention relates generally to inflatable restraint devices for motor vehicles, and more particularly to a method of folding such a device.
In recent years, engineering efforts in automobile safety systems have increasingly focused on inflatable restraint devices and methods/systems for their deployment. Of particular interest to designers are methods of folding the inflatable device or airbag to optimize the manner in which it deploys. Designs differ among the different types of airbags, for example, driver side, passenger side and side-impact airbags offer varying optimal deployment characteristics. Moreover, different vehicle structures as well as size and type of inflatable restraint apparatuses all provide different, sometimes competing considerations when developing airbag fold designs. For example, children or other relatively small occupants may have different requirements than larger occupants when it comes to optimizing vehicle safety systems. Complicating matters further, occupants may be out of a normal riding position during airbag deployment. There are thus continuing challenges to engineering broadly applicable systems that will operate effectively in view of the broad range of vehicle and occupant characteristics.
Further concerns relate to the equipment used in the inflatable restraint system other than the airbag itself. For instance, the inflator tends to be the heaviest, most expensive part of the system. Development of increasingly complex airbag structural and folding designs have been accompanied by the need for more powerful, and thus heavier and more complex inflators. Efficiency and production economics continue to drive engineering, however, and designers are therefore continually searching for ways to lighten and simplify restraint systems.
The present invention provides an airbag folding method comprising a plurality of steps. The method preferably begins by forming a set of pleats along each of a first and second edge of an airbag, the pleats having substantially equal depths. Next, a first half of the airbag is preferably folded a plurality of times, thereby forming a first fold body, and a second half of the airbag is preferably folded a plurality of times, thereby forming a second fold body. The pleats preferably form a plurality of adjacent layers extending along first and second edges of the airbag that upon supplying an inflation gas to an interior of the airbag resist unfolding, thereby directing the inflation gas initially predominantly into the first and second fold bodies.
Referring to
The method preferably begins by initially laying the subject airbag 10 substantially flat on a work surface such as a table. Although it is generally contemplated that the airbag will be folded manually, an automated system might be used without departing from the scope of the present invention. The various folding steps disclosed herein may be facilitated by substantially flattening each fold on the work surface (and therefore the entire airbag), however, the process can be carried out without flattening the airbag if desired. Referring to
Upon folding airbag 10 as illustrated in
Airbag 10 is preferably activated during or just prior to a crash or sudden vehicle deceleration. In a preferred embodiment, the associated vehicle is equipped with a crash sensor (not shown), which sends an electrical activation signal to a gas generator/inflator (also not shown) for supplying inflation gas to airbag 10. The signal preferably induces the rapid production/release of inflation gas in a manner well known in the art, which is supplied to an interior of airbag 10 via throat 14. The gas is preferably directed into airbag 10, causing relatively rapid inflation thereof. Airbag 10 bursts through or displaces the various airbag covers, trim panels, etc. used in housing the airbag system, in a manner also well known in the art. By forming a set of pleats X and Y along top and bottom edges 20 and 30, the regions of airbag 10 proximate the pleats tend to be more resistant to inflation than untucked regions of airbag 10.
Upon activation of airbag 10, gas is supplied to the airbag interior. The inflation gas is supplied via throat 14, and has a tendency to initially flow predominantly toward first and second halves 31 and 32. This is due to the fact that a relatively unobstructed pathway for the gas to flow exists in the directions of first and second halves 31 and 32 relative to throat 14, i.e. in a direction substantially perpendicular to centerline “C” . Gas flowing in a direction substantially along centerline C must force unfolding or untucking of the pleats along top and bottom edges 20 and 30. Thus, the present folding method induces gas to flow initially predominantly toward the folded first and second ends 31 and 32. As a result, folded first and second ends 31 and 32 initially inflate substantially as two separate side-by-side expanding lobes of airbag 10. As first and second ends 31 and 32 begin to fill with inflation gas, untucking of pleated regions X and Y begins. Essentially simultaneously, gas pressure induces expansion of airbag 10 proximate center Z. The expanding airbag pushes against first and second fold bodies 31 and 32, urging them outwardly. Utilizing lower folds 31a and 32a that hook outwardly relative to center Z increases the tendency for airbag 10 to inflate substantially outwardly relative to center Z.
Thus, during initial inflation, frictional interaction among the layers of pleated regions X and Y are resistive to inflation, giving the inflation gas the tendency to flow initially predominantly into fold bodies 31 and 32. By folding fold bodies 31 and 32 in the prescribed manner, the initial inflation of center Z enhances the tendency for outward expansion of airbag 10. Upon still further inflation, the inflation of airbag 10 proximate center Z will catch up with inflation of first and second halves 31 and 32. Eventually, the tucks are all untucked and airbag 10 will reach a fully inflated state. In a preferred embodiment, airbag 10 is mounted in a vehicle dashboard such that folded first and second ends 31 and 32 are positioned substantially left and right, respectively, of the center of the vehicle passenger seat. Thus, activation of airbag 10 preferably provides left and right expanding lobes positioned at left and right positions relative to a vehicle occupant. Accordingly, a center region of the airbag is “softer” than the respective left and right lobes. An occupant that impacts either of the left or right expanding lobes has a tendency to be guided toward the less expanded center region of the airbag. During certain crashes or other sudden vehicle deceleration wherein the occupant is out of a normal riding position, the expanding lobes can “scoop” an occupant toward the center region, reducing the risk of injury in some instances. Further, because the center region of the airbag inflates more slowly than the lateral, first and second regions 31 and 32, the risk of injury resulting from forceful projection of the center of the airbag toward an occupant's face, known in the art as “bag slapping,” can be lessened.
One preferred embodiment of the present invention has been set forth above, however, it should be appreciated that numerous variations are possible. For example, the number and dimensions of the various folds may be altered. Rather than four tucks along the top and bottom edges 20 and 30, a lesser or greater number of tucks might be made. Moreover, the number of tucks along top edge 20 and bottom edge 30 need not be the same. In some instances, it may be desirable to provide for relatively more or less rapid inflation of regions of the airbag proximate the top and bottom edges. In such applications, the number of tucks can be increased or decreased to increase or decrease, respectively, the resistance to inflation imparted by the tucks. Further, because of increased overlap of the layers of the airbag, and hence increased frictional interaction, it is believed that deeper tucks impart a greater resistance to inflation than relatively shallower tucks, and the depth of tucked regions may be varied accordingly.
The present description is for illustrative purposes only; the description and illustrations herein should not be construed to narrow the scope of the present invention in any way. Thus, those skilled in the art will appreciate that various alterations could be made to the presently disclosed embodiments without departing from the spirit and scope of the present invention. For instance, embodiments are contemplated in which tethers are utilized to assist in optimizing the deployment trajectory of the inflating airbag. The tethers may be attached at varying points in the airbag, and optimal designs depend on the specific vehicle dimensions. Such tethers have also been shown to be useful in volume control of the airbag. When the airbag is maximally expanded under the restraint of the tether(s), excess inflation gas can be discharged through vents in the airbag. Other aspects, features and advantages will be apparent upon an examination of the attached drawing figures and appended claims.
