Airbags with deployment control tethers

Abstract

The present invention discloses an airbag with a deployment control tether, which is a device that helps protect vehicle occupants, including: a curtain airbag that can be inflated from a storage state to a deployed state, in which the curtain airbag is positioned between the side structure of the vehicle and the vehicle occupant. The curtain airbag includes a mounting tab for mounting the curtain airbag to a support structure of the vehicle. The tether has a first tether end portion and a second tether end portion. The first tether end portion is connected to the inner side of the curtain airbag at and / or near the mounting tab. The second tether end portion is connected to the outer side of the curtain airbag. In the deployed state of the curtain airbag, the tether is tensioned and holds a portion of the curtain airbag adjacent to the second tether end portion, which is folded in an inner direction away from the side structure.

Description

Technical Field

[0001] The present invention relates to an apparatus that helps protect a vehicle occupant. More particularly, the present invention relates to an airbag that is inflatable between a vehicle occupant and a side structure of the vehicle. Background Art

[0002] As is well known, inflatable vehicle occupant protection devices inflate to help protect vehicle occupants in the event of a vehicle collision. One particular type of inflatable vehicle occupant protection device is an inflatable air curtain that is secured to a vehicle roof and / or a support structure adjacent to the vehicle roof. The inflatable air curtain is configured to inflate from the vehicle roof downward within the passenger compartment in the event of a side impact or vehicle rollover. The inflatable air curtain, when inflated, is positioned between a vehicle occupant and a side structure of the vehicle.

[0003] In certain vehicle models, portions of certain inflatable curtain airbags present a risk of deploying above and / or outboard of the vehicle's beltline. Deployment of portions of a curtain airbag above and / or outboard of the vehicle's beltline is undesirable because such portions may not be positioned between a vehicle occupant and the vehicle's side structure. Additionally, the at-risk portion of the curtain airbag may deploy to a location outboard of the vehicle and provide little protection to the vehicle occupant. To prevent such undesirable deployment, certain inflatable curtain airbags include a tether for controlling the deployment of the inflatable curtain airbag. Summary of the invention

[0004] According to one aspect, a device that helps protect a vehicle occupant includes a curtain airbag that is inflatable from a stored state to a deployed state, in which the curtain airbag is positioned between a side structure of a vehicle and a vehicle occupant. The curtain airbag includes a mounting tab for mounting the curtain airbag to a support structure of the vehicle. The tether has a first tether end portion and a second tether end portion. The first tether end portion is connected to an inboard side of the curtain airbag at and / or near the mounting tab. The second tether end portion is connected to an outboard side of the curtain airbag. In the deployed state of the curtain airbag, the tether is tensioned and holds a portion of the curtain airbag adjacent to the second tether end portion, which is folded in an inboard direction away from the side structure.

[0005] According to another aspect, alone or in combination with any other aspect, because the tether is connected to both the inner side and the outer side of the curtain airbag, the portion of the curtain airbag adjacent to the second tether end can be fully maintained on the inner side of the vehicle and restricted and / or prevented from pivoting on the outer side of the vehicle.

[0006] According to another aspect, alone or in combination with any other aspect, the second tether end portion can be sewn or otherwise connected to the outer side of the curtain airbag at the lower end portion of the curtain airbag. When the curtain airbag is in the deployed state, a portion of the lower end portion can be kept folded by the tether in an inner direction away from the side structure.

[0007] According to another aspect, alone or in combination with any other aspect, the first portion of the second tether end portion can be folded onto the second portion of the second tether end portion. The folded second tether end portion can be sewn or otherwise connected to the outer side of the curtain airbag at the lower end portion of the curtain airbag.

[0008] According to another aspect, alone or in combination with any of the other aspects, a tether may be tensioned and deployed when the curtain airbag inflates to limit and / or prevent a lower end portion of the curtain airbag from deploying outside the vehicle.

[0009] According to another aspect, alone or in combination with any other aspect, in the deployed state, the tether may extend from the second tether end portion to the first tether end portion in a rearward direction and toward the roof. Extension of the tether in the rearward direction and toward the roof may cause the lower end portion to remain folded further in the direction toward the roof and in the rearward direction.

[0010] According to another aspect, alone or in combination with any other aspect, the tension in the tether can be configured to increase when an occupant moving in an outboard direction impacts the curtain airbag. The increase in tension in the tether can resist the impact force directed outboard of the second tether end, thereby substantially preventing the portion of the curtain airbag proximate the second tether end from moving in the outboard direction.

[0011] According to another aspect, alone or in combination with any other aspect, the second tether end portion can be sewn or otherwise connected to the outer side of the curtain airbag at the lower end portion of the curtain airbag. Due to the increased tension in the tether, the lower end portion of the curtain airbag can be substantially prevented from moving toward the outside of the vehicle.

[0012] According to another aspect, alone or in combination with any other aspect, since the tether is connected to the outer side of the curtain airbag and the inner side of the curtain airbag at and / or near the mounting tab, the portion of the curtain airbag adjacent to the second tether end portion can be kept folded onto the adjacent portion of the curtain airbag to create a fold in the curtain airbag. The formation of the fold in the curtain airbag can cause the inner side of the curtain airbag adjacent to the second tether end portion to be folded onto the adjacent inner side portion of the curtain airbag so that the outer side of the curtain airbag adjacent to the second tether end portion faces in an inner direction.

[0013] According to another aspect, alone or in combination with any other aspect, the vertical height of the tether may be less than the vertical height of the curtain airbag. Since the vertical height of the tether is less than the vertical height of the curtain airbag, the portion of the curtain airbag immediately adjacent to the second tether end portion may remain folded toward the first tether end portion when the curtain airbag is in the deployed state.

[0014] According to another aspect, alone or in combination with any other aspect, the mounting tab may include overlapping layers of airbag material, wherein the mounting tab perforations extend through the overlapping layers. The first tether end portion may include a tether perforation extending therethrough. The first tether end portion may be positioned between the overlapping layers of the mounting tab with the tether perforation aligned with the mounting tab perforation.

[0015] According to another aspect, alone or in combination with any of the other aspects, the overlapping layers of mounting tabs may include a first portion folded over a second portion.

[0016] According to another aspect, alone or in combination with any other aspect, the device can further include a fastener having a portion extending through the mounting tab aperture and the tether aperture. A portion of the fastener can be configured to extend into a support structure of the vehicle to mount the device to the support structure.

[0017] According to another aspect, alone or in combination with any other aspect, the apparatus can further include a first bracket and a second bracket configured to interlock with each other. The first bracket and the second bracket can each have a bracket aperture extending therethrough. The first bracket can be positioned on an inner side of the mounting tab. The second bracket can be positioned on an outer side of the mounting tab and interlock with the first bracket. The first bracket aperture and the second bracket aperture can be aligned with the mounting tab aperture and the tether aperture.

[0018] According to another aspect, alone or in combination with any other aspect, the first portion of the first tether end portion can be folded onto the second portion of the first tether end portion. The first portion and the second portion of the first tether end portion can each have a tether perforation extending therethrough. The folded first tether end portion can be positioned between overlapping layers of the mounting tab with the tether perforation aligned with the mounting tab perforation.

[0019] According to another aspect, alone or in combination with any other aspect, the device can further include a fastener having a portion extending through the mounting tab aperture and the tether aperture. A portion of the fastener can be configured to extend into a support structure of the vehicle to mount the device to the support structure.

[0020] According to another aspect, alone or in combination with any of the other aspects, a portion of the first tether end portion may be sewn or otherwise attached to the inner side of the curtain airbag.

[0021] According to another aspect, alone or in combination with any other aspect, the first portion of the second tether end portion can be folded onto the second portion of the second tether end portion. The folded second tether end portion can be sewn or otherwise connected to the outer side of the curtain airbag.

[0022] According to another aspect, alone or in combination with any other aspect, the curtain airbag can include a plurality of mounting tabs spaced along the length of the upper portion of the curtain airbag. The first tether end portion can be connected to the inner side of the curtain airbag at and / or near one of the mounting tabs.

[0023] According to another aspect, an apparatus for assisting in protecting a vehicle occupant may include a curtain airbag inflatable from a stored state to a deployed state in which the curtain airbag is positioned between a side structure of a vehicle and a vehicle occupant. The tether may have a first tether end portion and a second tether end portion. The first tether end portion may be connected to an inner side of the curtain airbag at and / or near an upper portion of the curtain airbag. The second tether end portion may be connected to an outer side of the curtain airbag at a lower end portion of the curtain airbag. When the curtain airbag is deployed, the tether may substantially prevent the lower end portion from deploying to an outer side of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and other features of the present invention will become apparent to those skilled in the art to which the present invention relates by considering the following description of the present invention with reference to the accompanying drawings, in which:

[0025] Figure 1 is a schematic side view showing a device that helps protect a vehicle occupant;

[0026] Figure 2 yes Figure 1 A side view of an element of a device;

[0027] Figure 3 yes Figure 2 a cross-sectional view of a portion of a device;

[0028] Figure 4 yes Figure 1 A side view of an element of a device;

[0029] Figure 5 yes Figure 1 a side view of a portion of the device; and

[0030] Figure 6 yes Figure 5A front view of a portion of the device;

[0031] Figure 7 yes Figure 1 a side view of a portion of a device;

[0032] Figure 8 yes Figure 1 A schematic front view of a portion of a device; and

[0033] Figure 9-Figure 22 Shown for assembly Figure 1 A method of a portion of a device. DETAILED DESCRIPTION

[0034] An apparatus 10 to help protect an occupant 12 of a vehicle 14 includes an inflatable vehicle occupant protection device 16 in the form of an airbag, such as a curtain airbag, for helping to protect the occupant in the event of a side impact of the vehicle. Figure 1 In the illustrated embodiment, the curtain airbag 16 is shown on the driver's side 18 of the vehicle 14 to help protect the driver's side vehicle occupant. It should be understood by those skilled in the art that the apparatus 10 disclosed herein may be adapted for use on the passenger side (not shown) of the vehicle 14 to help protect the passenger's side vehicle occupant.

[0035] Figure 1 1, various portions of the occupant 12 are shown, such as the occupant's head 20 and torso 22. The vehicle 14 includes at least one vehicle seat 24 for the vehicle occupant 12, a steering wheel 26, a roof 28, and a side structure 30. The vehicle 14 has two rows of seats, which helps indicate the configuration of the side structure 30. Figure 1 In the example configuration shown, the side structure 30 of the vehicle 14 includes two doors 32, two side windows 34, a roof rail 36, an A-pillar 38, a B-pillar 40, and a C-pillar 42. However, the apparatus 10 may be applied to vehicles having any number of rows, and therefore any side structure configuration.

[0036] The curtain airbag 16 may be constructed of any suitable material, such as nylon (e.g., woven nylon 6-6 yarn), and may be constructed in any suitable manner. For example, the curtain airbag 16 may have a one-piece woven (OPW) construction, in which the curtain airbag is woven into a single piece of material. As another example, the curtain airbag 16 may include more than one piece of material. If more than one piece of material is used, the pieces may be interconnected by known means, such as stitching, ultrasonic welding, thermal bonding, or adhesives, to form the curtain airbag 16. The curtain airbag 16 may be uncoated, coated with a material, such as an airtight urethane, or laminated with a material, such as an airtight film. Thus, the curtain airbag 16 may have an airtight or substantially airtight construction. It will be appreciated by those skilled in the art that alternative materials, such as polyester yarns, and alternative coatings, such as silicone, may also be used to construct the curtain airbag 16.

[0037] like Figure 1 As shown in the example construction of , the curtain airbag 16 is mounted to a support structure 44 of the vehicle 14 such that when the curtain airbag is in the stored state, at least a portion of the curtain airbag is contained within the support structure. The curtain airbag 16 is inflatable and can be deployed from the stored state away from the support structure 44 and toward a deployed state in which the curtain airbag is positioned between the side structure 30 and the vehicle occupant 12. The support structure 44 can be any structure in the vehicle 14 that will accommodate the curtain airbag 16 deployed therefrom such that the deployed curtain airbag is positioned between the side structure 30 and the vehicle occupant 12. Figure 1 In the example construction shown, the support structure 44 is a roof rail 36. The curtain airbag 16 may be mounted to the roof rail 36 in any manner known in the art. Figure 1 In the example construction shown, the curtain airbag 16 includes a plurality of mounting tabs 46 spaced along the length of an upper portion 48 of the curtain airbag. A fastener 50 is provided at each mounting tab 46 to mount the curtain airbag 16 of the apparatus 10 to the roof rail 36.

[0038] The inflator 52 is operatively connected to the inflatable volume 54 of the curtain airbag 16 in any known manner. Figure 1In an example construction of the curtain airbag 16, the curtain airbag 16 has an inflator port 56 in fluid communication with the inflatable volume 54. The inflator 52 is mounted to the roof rail 36 of the vehicle 14 via an inflator bracket 58 and is connected to and / or received in the inflator port 56 of the curtain airbag 16. The inflator 52 is actuatable to provide inflation fluid to the inflatable volume 54 of the curtain airbag 16, thereby inflating the curtain airbag and deploying it from a stored state to a deployed state. The inflator 52 can be of any known type, such as stored gas, solid propellant, enhanced, or hybrid. The airbag controller 60 can be operatively connected to the inflator 52 via a lead 62. The airbag controller 60 is configured to actuate the inflator 52 in response to sensing the occurrence of an event requiring occupant protection.

[0039] Upon occurrence of an event requiring occupant protection, such as a collision, the airbag controller 60 actuates the inflator 52 to provide inflation fluid to the inflatable volume 54 of the curtain airbag 16, thereby inflating and deploying the curtain airbag from the stored state to the deployed state. The curtain airbag 16 is deployed in a generally downward direction away from the roof rail 36 (e.g., Figure 1 In order to adequately provide the vehicle occupant 12 with adequate protection, the curtain airbag 16 should also be deployed to a position inboard of the waistline 64 of the vehicle 14 so that the deployed curtain airbag is positioned between the side structure 30 and the vehicle occupant 12 on the vehicle interior (see FIG. Figure 1 and Figure 8 ).

[0040] Certain features of the vehicle 14 and the apparatus 10 enable portions of the curtain airbag 16 to deploy to a position inboard of the beltline 64. As the curtain airbag 16 deploys in the downward direction A, portions of the curtain airbag may engage portions of the side structure 30 of the vehicle 14. This engagement between the side structure 30 and the curtain airbag 16 helps prevent portions of the curtain airbag from deploying to a position on and / or outboard of the beltline 64. For example, the pillars 38, 40, 42 engage the deploying curtain airbag 16 and help prevent portions of the curtain airbag adjacent to these pillars from being positioned on and / or outboard of the beltline 64. Additionally, the mounting tabs 46 along the upper portion 48 of the curtain airbag 16 hold the upper portion of the curtain airbag inboard of the beltline 64 and help prevent the upper portion of the curtain airbag from deploying to a position above and / or outboard of the beltline.

[0041] Even with the pillars 38, 40, 42 and mounting tabs 46, other portions of the curtain airbag 16 may still be at risk of deploying to a position above and / or outside the beltline 64 without additional protection. In certain vehicle models, the lower end portion 66 (such as the lower front end portion 68) at the lower portion 70 of the curtain airbag 16 may be at risk of deploying to a position above and / or outside the beltline 64. To prevent such undesirable deployment, the device 10 includes a tether 72 that helps prevent the potentially at-risk portion of the curtain airbag 16 from deploying to a position above and / or outside the beltline 64. Although the following description primarily describes the tether 72 helping to prevent such undesirable deployment of the lower front end portion 68 of the curtain airbag 16, it will be understood by those skilled in the art that the tether may be adapted to help prevent similar undesirable deployment of any other portion of the curtain airbag (such as, but not limited to, the lower rear end portion 74 of the curtain airbag).

[0042] The tether 72 may be formed from a length of material, such as a single length of material, or from multiple lengths of material that are connected to each other to collectively form the length of material. The material used to form the tether 72 may be the same material as the curtain airbag 16, or may be made of any other suitable material. The tether 72 has a first tether end portion 76 that is connected to the inner side 78 of the curtain airbag 16 at and / or near the upper portion 48 of the curtain airbag by known means, such as by sewing, ultrasonic welding, heat bonding, adhesives, fasteners, or any combination thereof. Figure 2-Figure 3 In the example construction shown, the first tether end portion 76 is connected to the upper portion 48 of the curtain air bag 16 at one of the mounting tabs 46 .

[0043] like Figure 2-Figure 3 As shown, the mounting tab 46 may include an integrally woven portion of the OPW curtain airbag 16. The first portion 80 of the OPW curtain airbag 16 may be folded onto the second portion 82 to define an overlapping layer 84 of the mounting tab 46. A portion of the first tether end portion 76 may be positioned between the overlapping layers 84 of the mounting tab 46. A portion of the fastener 50 extends through the mounting tab 46 and the tether 72 to connect the tether to the mounting tab. A portion of the fastener 50 is also configured to extend into the roof rail 36 of the vehicle 14 to mount the device 10 to the roof rail.

[0044] The fastener 50 may be any fastener capable of withstanding the deployment forces of the deploying curtain airbag 16 and capable of extending through the mounting tab 46, the first tether end portion 76, and into the roof rail 36 of the vehicle 14. Figure 2-Figure 3In an example configuration of the fastener 50, the fastener 50 is a threaded fastener, such as a bolt or screw, having a head 86 and a stem 88. The stem 88 extends through a mounting tab aperture 90 extending through each of the first portion 80 and the second portion 82 of the stacking layer 84 and through at least one tether aperture 92 extending through the first tether end portion 76. To accommodate the extension of the stem 88 through the mounting tab 46 and the tether 72, the at least one tether aperture 92 is aligned with the mounting tab aperture 90 when the first tether end portion 76 is positioned between the stacking layers 84 of the mounting tabs. A portion of the stem 88 is also configured to extend into the roof rail 36 of the vehicle 14 to mount the device 10 to the roof rail.

[0045] As will be discussed below, during deployment, the curtain airbag 16 exerts a downward deployment force F1 on the tether 72, which causes the first tether end portion 76 to move in the downward direction A. The fastener 50 extending through the at least one tether penetration hole 92 helps prevent the first tether end portion 76 from moving in the downward direction A and from separating from a desired position on the curtain airbag 16. For example, a portion of the downward force F1 acts on the stem 88 of the threaded fastener 50 through the at least one tether penetration hole 92. Because the threaded fastener 50 is held in place by being inserted into the roof rail 36, the threaded fastener resists the downward deployment force F1 provided by the at least one tether penetration hole 92 and prevents the first tether end portion 76 from moving in the downward direction. The reaction of the threaded fastener 50 can be viewed as moving in a direction toward the roof (e.g., toward the roof). Figure 3 The force (shown by arrow "B") Figure 3 (as indicated by the arrow “F2” in the figure).

[0046] If the tether 72 has only one tether penetration hole 92, then the reaction downward force F1 and the upward force F2 towards the roof at the one tether penetration hole will cause a tear in the tether to develop at the one tether penetration hole. A tear at the one tether penetration hole 92 will cause the tether 72 to detach from the mounting tab 46 and the device 10 to fail. In order to strengthen the tether 72 and prevent the development of a tear at the single tether penetration hole 92, the first portion 94 of the first tether end portion 76 can be folded onto the second portion 96 of the first tether end portion. Figure 4 As shown, each of the first portion 94 and the second portion 96 of the first tether end portion includes a tether perforation 92. Once the first portion 94 of the first tether end portion 76 is at the fold line (eg, Figure 4 folded onto the second portion 96 of the first tether end portion) so that the tether perforation 92 on the first portion is aligned with the tether perforation on the second portion. Figure 3As shown, the folded first tether end portion 76 is positioned between the overlapping layers 84 of the folded mounting tab 46 with the tether aperture 92 aligned with the mounting tab aperture 90. In this configuration, the fastener 50 extends through the mounting tab aperture 90 and the tether aperture 92.

[0047] Because both the first portion 94 and the second portion 96 of the first tether end portion 76 have tether penetration holes 92 through which the stem 88 of the fastener 50 extends, the reaction downward force F1 and the roof-facing force F2 are split between each of the tether penetration holes of the first and second portions of the first tether portion, rather than being applied to a single tether penetration hole. This split prevents the entire load of the reaction downward force F1 and the roof-facing force F2 from being applied to a single tether penetration hole 92, thereby helping to minimize the development of tears at the tether penetration holes.

[0048] In addition to being connected to the mounting tab 46, a portion of the first tether end portion 76 may be sewn or otherwise connected to the inner side 78 of the curtain airbag 16 near the upper portion 48 of the curtain airbag. Figure 1-Figure 3 In the example construction shown, a portion of the first tether end portion 76 is sewn adjacent the mounting tab 46 to which the first tether end portion is attached (eg, Figure 1-Figure 3 50) to the inner side 78 of the curtain air bag 16. The sewing of the first tether end portion 76, in addition to the fastener 50, substantially prevents the first tether end portion from moving in the downward direction A. Thus, the sewing of the first tether end portion 76 provides an additional level of reinforcement. Although the first tether end portion 76 has been described as being connected to one of the mounting tabs 46 by the fastener 50 and sewn to the inner side 78 of the curtain air bag 16, it should be understood by those skilled in the art that the first tether end portion may be connected to the inner side of the curtain air bag by only one of the described methods and / or by any method known in the art.

[0049] The tether 72 further includes a second tether end portion 98 that is connected to an outboard side 100 of the curtain airbag 16 by known means, such as by fasteners, stitching, ultrasonic welding, heat bonding, adhesives, or any combination thereof. Figure 1 In the example construction shown, the second tether end portion 98 is sewn or otherwise attached to the lower front end portion 68 of the curtain airbag (eg, Figure 1 To enhance the connection between the second tether end portion 98 and the second tether end portion and the curtain airbag 16, the first portion 102 of the second tether end portion may be sewn or otherwise connected to the curtain airbag (see FIG. Figure 1 and Figure 4 ) before the fold line ( Figure 4 folded onto the second portion 104 of the second tether end portion. Figure 1 As shown, the folded second tether end portion 98 may then be sewn to the outboard side 100 of the curtain airbag 16 at the lower front end portion 68 of the curtain airbag.

[0050] Figure 5-Figure 6 The tether 72 is shown connected to the curtain airbag 16 before the curtain airbag is rolled / folded and attached to the roof rail 36. As shown, the first tether end portion 76 is connected to the inner side 78 of the curtain airbag at and / or near one of the mounting tabs 46. Figure 5 In the example construction shown, the vertical height 106 of the tether 72 is less than the vertical height 108 of the curtain airbag 16. The vertical heights 106, 108 of the tether 72 and the curtain airbag 16 are measured in the vehicle up-down direction BA (a combination of the direction B toward the roof and the downward direction A). Therefore, for example, even if the tether 72 extends diagonally, its vertical height 106 is the vertical vehicle up-down BA component of the diagonal extension. Due to this height difference, the outer side surface 100 of the lower front end portion 68 of the curtain airbag 16 is folded toward the first tether end portion 76 to accommodate the connection of the second tether end portion to the outer side surface of the curtain airbag at the lower front end portion. Because the first tether end portion 76 is connected to the inner side surface 78 of the curtain airbag, the outer side surface 100 of the lower front end portion 68 of the curtain airbag 16 in the inner direction (such as the inner side) is folded. Figure 6 The first tether end portion of the curtain airbag 16 is folded toward the first tether end portion (as indicated by arrow "C" in the figure) to create a fold 110 in the curtain airbag. The formation of the fold 110 causes the inner side 78 of the curtain airbag 16 at the lower front end portion 68 to fold onto the adjacent inner side portion of the curtain airbag so that the outer side 100 of the curtain airbag at the lower front end portion faces the inner direction C.

[0051] exist Figure 5-Figure 6 In the example configuration of Figure 5The lower front end portion 68 of the curtain airbag 16 is folded in the inboard direction C, the roof direction B, and the rearward direction D to the first tether end portion 76. The lower front end portion 68 of the curtain airbag 16 is thus folded in the inboard direction C, the roof direction B, and the rearward direction D to the adjacent portion of the curtain airbag, so that the tether 72 can extend from the second tether end portion 98 to the first tether end portion 76 in the rearward direction and the roof direction. The curtain airbag 16 can then be rolled up / folded in any desired manner and attached to the roof rail 36 to place the curtain airbag in the storage state. In an exemplary configuration, the curtain airbag 16 is arranged in an outboard direction (eg Figure 6 However, those skilled in the art will appreciate that the curtain airbag 16 may be rolled up along the inner direction C or folded in any other manner.

[0052] When the curtain airbag 16 is deployed in the downward direction A to Figure 1 1, the lower front end portion 68 of the curtain airbag pulls the second tether end portion 98 downward due to the downward deployment force F1. As a result, the tether 72 becomes tensioned between the first tether end portion 76 and the second tether end portion 98. The tensioned tether 72 thus resists the downward deployment force F1 applied by the deploying curtain airbag 16. This reaction can be viewed as a force in the direction B toward the roof, as shown in FIG. Figure 7 As shown by arrow "F2" in FIG. As the tether 72 becomes tensioned, it eventually prevents the lower front end portion 68 of the curtain airbag 16 from further deploying in the downward direction A.

[0053] The difference in vertical heights 106, 108 ("height difference") between the tether 72 and the curtain airbag 16 causes the tether to become tensioned before the curtain airbag is fully deployed / extended. Specifically, the height difference causes the tether 72 to become tensioned before the lower front end portion 68 of the curtain airbag 16 and the portion of the curtain airbag adjacent to the lower front end portion are fully deployed / extended. Thus, the tether 72 limits and / or prevents at least the lower front end portion 68 of the curtain airbag 16 from fully deploying / extending. Although the vertical height 106 of the tether 72 is described as being less than the vertical height 108 of the curtain airbag 16, the tether may have any desired vertical height, as long as the tether is appropriately tensioned to limit and / or prevent the desired portion of the curtain airbag from fully deploying / extending.

[0054] As the curtain airbag 16 inflates and deploys, the tether 72 limits and / or prevents the lower front end portion 68 of the curtain airbag from fully opening / extending. In this way, the tether 72 helps maintain the fold 110 in the lower front end portion 68. The lower front end portion 68 of the curtain airbag 16 and / or a portion of the curtain airbag immediately adjacent to the second tether end portion 98 is thus maintained folded toward adjacent portions of the curtain airbag in the inboard direction C, toward the roof direction B, and toward the rearward direction D. Figure 7 As shown, when the curtain airbag 16 is in the deployed state, the inner side 78 of the curtain airbag at the lower front end portion 68 is folded onto the adjacent portion of the curtain airbag, and the outer side 100 of the curtain airbag at the lower front end portion faces the inner direction C.

[0055] like Figure 8 As shown, the tether 72 thus holds the lower front end portion 68 of the curtain airbag 16 and / or a portion of the curtain airbag immediately adjacent to the second tether end portion 98 folded in the inboard direction C away from the side structure 30 of the vehicle 14 and away from the waistline 64. This causes the lower front end portion 68 of the curtain airbag 16 to deploy to a position inboard of the waistline 64 and correspondingly inboard of the vehicle 14. While holding the lower front end portion 68 of the curtain airbag 16 folded in the inboard direction C away from the waistline 64, the tether 72 also limits and / or prevents the lower front end portion of the curtain airbag from pivoting in the outboard direction E toward a position above and / or outboard of the waistline.

[0056] Although the tether 72 is largely described and illustrated as retaining only the lower front end portion 68 of the curtain airbag 16 that is folded in the inboard direction C, the tether may also retain other portions of the lower portion 70 of the curtain airbag that are folded in the inboard direction. This results in the tether 72 retaining a greater length of the lower portion 70 of the curtain airbag 16 that is folded in the inboard direction, and thus ensuring that a greater length of the lower portion of the curtain airbag is deployed to a position located inboard of the beltline 64. Furthermore, although the first tether end portion 76 is described as being connected to the inboard side 78 of the curtain airbag 16 at and / or near the upper portion 48 of the curtain airbag, the first tether end portion may be connected to the inboard side of the curtain airbag at any desired location that appropriately limits and / or prevents the desired portion of the curtain airbag from fully opening / deploying.

[0057] In addition to the tethers 72 substantially preventing portions of the curtain air bag 16 from deploying to undesirable positions, the tethers also support the curtain air bag against impact forces when the curtain air bag is in the deployed state. In certain collisions, the occupant 12 may move in the outboard direction E to impact the deployed curtain air bag. Figure 8 As shown, the outboard moving occupant 12 thus provides a force in the outboard direction E to the deployed curtain airbag, such as Figure 8As shown by the arrow "F3" in the middle. Portions of the side structure 30 that are positioned against and / or adjacent to the outer side 100 of the deployed curtain airbag 16 provide reaction surfaces for supporting the curtain airbag against these outer side forces. However, other portions of the deployed curtain airbag 16 may not be supported by the side structure 30 and therefore may be at risk of being moved above and / or outside the waistline 64 by the outer side force F3. In some vehicle modules, a portion of the deployed curtain airbag 16 that is adjacent to the second tether end portion 98 may be at risk of being moved above and / or outside the waistline 64 by the outer side force F3. The tether 72 can sufficiently help prevent these portions of the curtain airbag 16 from moving above and / or outside the waistline 64.

[0058] As the portion of the deploying curtain airbag 16 proximate the second tether end portion 98 is urged in the outboard direction E, the second tether end portion is urged further away from the first tether end portion 76. As discussed above, the tension in the tether 72 increases as the second tether end portion 98 travels further away from the first tether end portion 76. Once the tether 72 becomes tensioned, the second tether end portion 98 is substantially prevented from moving further away from the first tether end portion 76. Because the tether 72 is tensioned when the curtain airbag 16 is in the deployed state, the second tether end portion 98 is substantially prevented from moving any further away from the first tether end portion 76. The tether 72 thus resists the outboard force F3 acting on the curtain airbag 16 proximate the second tether end portion 98. The reaction of the tether 72 can be viewed as a force in the inboard direction, as shown in FIG. Figure 8 This inboard reaction force F4 of the tether 72 substantially prevents the portion of the curtain airbag 16 proximate the second tether end portion 98 from moving above and / or outside the waistline 64 in the outboard direction E. Even if a portion of the curtain airbag 16 proximate the second tether end portion 98 temporarily moves above and / or outside the waistline 64, the inboard reaction force F4 of the tether 72 will tend to pull that portion of the curtain airbag back to the inside of the waistline.

[0059] Although the tether 72 is largely described and illustrated as preventing only a portion of the curtain air bag 16 immediately adjacent the second tether end portion 98 from moving above and / or outside the waistline 64 in the outboard direction E, the tether may also prevent other portions of the lower portion 70 of the curtain air bag from moving above and / or outside the waistline in the outboard direction. This results in the tether 72 preventing a greater length of the lower portion 70 of the curtain air bag 16 from moving above and / or outside the waistline 64, thereby ensuring that a greater length of the lower portion of the curtain air bag remains in a position located inboard of the waistline.

[0060] Figure 9-Figure 22 Shows that it can be assembled Figure 1The example process of the device 10 shown in the figure is not intended to limit the way of assembling the device 10. It should be understood by those skilled in the art that certain steps of the following example process may be performed before and / or after certain other steps of the process, whether or not explicitly stated or shown. Fig. 9 As shown, the mounting tab 46 is an integral part of the OPW curtain air bag 16 having a first portion 80 and a second portion 82 with mounting tab apertures 90 extending therethrough. Fig. 9 The illustrated mounting tab 46 further includes an auxiliary aperture 112 extending through the first and second portions 80 , 82 of the mounting tab.

[0061] like Fig.10 As shown, the tether 72 is configured to have a first tether end portion 76 and a second tether end portion 98. The first end tether portion 76 may have a first portion 94 and a second portion 96, wherein the tether perforation 92 extends through the first portion and the second portion. The first portion 94 and the second portion 96 of the first tether end portion 76 further include an auxiliary perforation 114 extending therethrough. The second tether end portion 98 is spaced apart from the first tether end portion 76 and is spaced apart from the first tether end portion 76 at a predetermined angle (e.g., Fig.10 This angled configuration of the tether 72 allows the first tether end portion 76 to mate with the shape of the mounting tab 46 (see Fig.11 ), while also allowing the tether to extend from the second tether end portion 98 to the first tether end portion in a roof-facing direction B and a rearward direction D.

[0062] like Fig.11 As shown, the first tether end portion 76 can be positioned on the mounting tab 46, wherein the tether penetration hole 92 of the first portion 94 of the first tether end portion is aligned with the mounting tab penetration hole 90 of the first portion 80 of the mounting tab 46. The tether penetration hole 92 of the second portion 96 of the first tether end portion 76 is also aligned with the mounting tab penetration hole 90 of the second portion 82 of the mounting tab 46. In addition, the auxiliary penetration hole 114 of the first portion 94 of the first tether end portion 76 is aligned with the auxiliary penetration hole 112 of the first portion 80 of the mounting tab 46. The auxiliary penetration hole 114 of the second portion 96 of the first tether end portion 76 is also aligned with the auxiliary penetration hole 112 of the second portion 82 of the mounting tab 46. As shown in FIG. Fig.12 As shown, once the first tether end portion 76 is positioned on and aligned with the mounting tab 46, a portion of the first tether end portion can be sewn or otherwise attached (eg, Fig.12 ) to the inner side 78 of the curtain airbag 16. The connection can be adjacent to the mounting tab 46 and / or the upper portion 48 of the curtain airbag 16.

[0063] like Figure 12-13 As shown, the first portion 94 of the first tether end portion 76 and the first portion 80 of the mounting tab 46 can then be folded around the fold line ( Fig.12 The folded first tether end portion 76 is folded onto the second portion 96 of the first tether end portion and the second portion 82 of the mounting tab. The folded first portion 80 and second portion 82 of the mounting tab 46 define an overlapping layer 84 of mounting tabs. Thus, in this configuration, the folded first tether end portion 76 is positioned between the overlapping layers 84 of the mounting tabs 46.

[0064] A first bracket 116 and a second bracket 118 may be provided, for example, at Fig.14 and Fig.15 The brackets shown in the figure provide additional support for the folded mounting tabs 46 and the first tether end portion 76. The first bracket 116 and the second bracket 118 are plates formed at least in part from steel, aluminum, plastic, any other suitable material, or any combination thereof. Fig.14 The first bracket 116 is shown having a first bracket through-hole 120 extending therethrough and at least one interlocking feature 122 in the form of a recess extending through the first bracket. The first bracket 116 is shown as having two recesses 122. Fig.15 The second bracket 118 is shown having a second bracket aperture 124 extending therethrough and at least one interlocking feature 126 in the form of an arm. The second bracket 118 is shown having two arms 126 corresponding to the two recesses 122 of the first bracket 116. The arms 126 of the second bracket 118 are configured to be positioned in the recesses 122 of the first bracket 116 to interlock the first bracket and the second bracket.

[0065] like Fig.16 As shown, the first bracket 116 can be positioned on the inner side 128 of the mounting tab on the folded first portion 80 of the mounting tab 46. The first bracket 116 is aligned on the mounting tab 46, wherein the first bracket aperture 120 is aligned with the mounting tab aperture 90 and the tether aperture 92, and the recess 122 is aligned with the auxiliary aperture 112 of the mounting tab and the auxiliary aperture 114 of the tether 72. Figure 17-Figure 18As shown, the second bracket 118 can then be positioned on the second portion 82 of the mounting tab 46 on the outer side 130 of the mounting tab. The second bracket 118 is aligned on the mounting tab 46, wherein the second bracket aperture 124 is aligned with the mounting tab aperture 90 and the tether aperture 92. The arm 126 of the second bracket 118 extends through the auxiliary aperture 112 of the mounting tab 46, the auxiliary aperture 114 of the first tether end portion 76, and the recess 122 of the first bracket 116. As the arm 126 extends through the recess 122, at least a portion of the arm engages with the face 132 of the first bracket 116 to interlock the first bracket 118 with the second bracket 118. In addition, by extending through the auxiliary aperture 112 of the mounting tab 46 and the auxiliary aperture 114 of the tether 72 to interlock the first bracket 116 with the second bracket 118, the arm 126 at least partially retains the folded first tether end portion 76 between the overlapping layers 84 of the mounting tab.

[0066] The washer 134 can then be slid onto the shank 88 of the threaded fastener 50. Figure 19-20 As shown, with the washer 134 positioned on the stem 88, a portion of the stem is inserted through the first bracket aperture 120, the mounting tab aperture 90 of the first portion 80 of the mounting tab 46, the tether aperture 92, the mounting tab aperture of the second portion 82 of the mounting tab, and through the second bracket aperture 124 so that the head 86 of the threaded fastener and the washer are positioned on the inner side 128 of the mounting tab. Fig. 20 As shown, the retainer 136 can then be slid from the outer side 130 of the mounting tab 46 onto the rod 88 to retain the threaded fastener 50 extending through the mounting tab, the tether 72, the first bracket 116 and the second bracket 118. The retainer 136 also retains the folded first tether end portion 76 between the overlapping layers 84 of the mounting tab 46.

[0067] like Fig.21 As shown, the outer side 100 of the lower front end portion 68 of the curtain airbag 16 can then be folded in the inboard direction C toward the first tether end portion 76 so that the inboard side 78 of the curtain airbag at the lower front end portion of the curtain airbag is folded onto the adjacent inboard side portion of the curtain airbag. In this configuration, the outer side 100 of the folded lower front end portion 68 faces the inboard direction C. The first portion 102 of the second tether end portion 98 can be folded at the fold line ( Fig.21 folded onto the second portion 104 of the second tether end portion. Fig. 22 As shown, the folded second tether end portion 98 can then be sewn or otherwise connected at the folded lower front end portion 68 of the curtain airbag (e.g. Fig. 22 ) to the outer side 100 of the curtain airbag 16.

[0068] Based on the above description of the present invention, those skilled in the art will recognize improvements, changes and modifications. These improvements, changes and modifications within the technical scope of the art are intended to be covered by the appended claims.

Claims

1. A device for assisting in protecting a vehicle occupant, comprising: a curtain airbag inflatable from a stored state to a deployed state in which the curtain airbag is positioned between a side structure of the vehicle and a vehicle occupant, the curtain airbag including a mounting tab for mounting the curtain airbag to a support structure of the vehicle; as well as a tether having a first tether end portion connected to an inboard side of the curtain airbag at or near the mounting tab and a second tether end portion connected to an outboard side of the curtain airbag; wherein, in the deployed state of the curtain airbag, the tether is tensioned and holds a portion of the curtain airbag adjacent to the second tether end portion, the second tether end portion being folded in a direction away from the inner side of the side structure, and wherein the mounting tab comprises overlapping layers of airbag material, the mounting tab perforations extending through the overlapping layers, and wherein the first tether end portion comprises a tether perforation extending therethrough, the first tether end portion being positioned between the overlapping layers of the mounting tab with the tether perforations aligned with the mounting tab perforations.

2. The device according to claim 1, wherein: Since the tether is connected to both the inner side and the outer side of the curtain airbag, the portion of the curtain airbag proximate the second tether end is substantially held inside the vehicle and is restricted or prevented from pivoting outside the vehicle.

3. The device according to claim 1, wherein: The second tether end portion is sewn or otherwise connected to the outer side of the curtain airbag at the lower end portion of the curtain airbag, and when the curtain airbag is in a deployed state, a portion of the lower end portion is held folded by the tether in an inner direction away from the side structure.

4. The device according to claim 3, wherein: The first portion of the second tether end portion is folded onto the second portion of the second tether end portion, and the folded second tether end portion is sewn or otherwise connected to an outer side surface of the curtain airbag at a lower end portion of the curtain airbag.

5. The device according to claim 3, wherein: The tether is tensioned and deployed when the curtain airbag is inflated to restrict or prevent a lower end portion of the curtain airbag from being deployed outside the vehicle.

6. The device according to claim 3, wherein: In the deployed state, the tether extends from the second tether end portion to the first tether end portion in a rearward direction and toward the roof, and the extension of the tether in the rearward direction and toward the roof causes the lower end portion to remain folded further in the direction toward the roof and in the rearward direction.

7. The device according to claim 1, wherein: The tension in the tether is configured to increase when an occupant moving in an outboard direction impacts the curtain airbag, the increase in tension in the tether resisting an outboard-directed impact force proximate to an end of the second tether, thereby substantially preventing a portion of the curtain airbag proximate to the end of the second tether from moving in an outboard direction.

8. The device according to claim 7, wherein: The second tether end portion is sewn or otherwise connected to an outer side of the curtain airbag at a lower end portion of the curtain airbag, and wherein the lower end portion of the curtain airbag is substantially prevented from moving toward the outside of the vehicle due to increased tension in the tether.

9. The device according to claim 1, wherein: Since the tether is connected to the outer side of the curtain airbag and the inner side of the curtain airbag at or near the mounting tab, a portion of the curtain airbag adjacent to the second tether end portion remains folded onto an adjacent portion of the curtain airbag to create a fold in the curtain airbag, and the formation of the fold in the curtain airbag causes the inner side of the curtain airbag adjacent to the second tether end portion to fold onto an adjacent inner side portion of the curtain airbag so that the outer side of the curtain airbag adjacent to the second tether end portion faces in an inner direction.

10. The device according to claim 1, wherein: The vertical height of the tether is smaller than the vertical height of the curtain airbag, and wherein, because the vertical height of the tether is smaller than the vertical height of the curtain airbag, a portion of the curtain airbag proximate to the second tether end portion remains folded toward the first tether end portion when the curtain airbag is in a deployed state.

11. The device according to claim 1, wherein: The overlapping layers of mounting tabs include a first portion folded over a second portion.

12. The apparatus of claim 1 , further comprising a fastener having a portion extending through the mounting tab aperture and the tether aperture, and wherein a portion of the fastener is configured to extend into a support structure of a vehicle to mount the apparatus to the support structure.

13. The device according to claim 1 further includes a first bracket and a second bracket configured to interlock with each other, the first bracket and the second bracket each having a bracket perforation extending therethrough, the first bracket being positioned on the inner side of the mounting tab, the second bracket being positioned on the outer side of the mounting tab and interlocking with the first bracket, and the first bracket perforation and the second bracket perforation being aligned with the mounting tab perforation and the tether perforation.

14. The apparatus according to claim 1, wherein: A first portion of the first tether end portion is folded onto a second portion of the first tether end portion, the first portion and the second portion of the first tether end portion each having a tether perforation extending therethrough, the folded first tether end portion being positioned between overlapping layers of the mounting tab with the tether perforation aligned with the mounting tab perforation.

15. The apparatus of claim 14, further comprising a fastener having a portion extending through the mounting tab aperture and the tether aperture, and wherein a portion of the fastener is configured to extend into a support structure of a vehicle to mount the apparatus to the support structure.

16. The device according to claim 15, wherein: A portion of the first tether end portion is sewn or otherwise attached to an inner side of the curtain airbag.

17. The device according to claim 16, wherein: The first portion of the second tether end portion is folded onto the second portion of the second tether end portion, and the folded second tether end portion is sewn or otherwise connected to the outer side of the curtain airbag.

18. The apparatus according to claim 1, wherein: The curtain airbag includes a plurality of mounting tabs spaced along a length of an upper portion of the curtain airbag, and wherein the first tether end portion is connected to an inner side of the curtain airbag at or near one of the mounting tabs.

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