Airbag module suitable for mounting to the roof of a vehicle, housing component for use in such an airbag module and vehicle having such an airbag module

Abstract

An airbag module adapted to be mounted to a roof (R) of a vehicle is described. The airbag module comprises an airbag cushion (55), an inflator in fluid communication with the airbag cushion (55) and a housing component (20). The housing component (20) comprises a front section defining a portion of a cover for the airbag cushion (55) when mounted to the roof (R) of the vehicle. The front section comprises a first mounting flange (32) and a second mounting flange (38) which are located in a first plane (E1), a bottom wall (35) which is located in a second plane (E2) which is distanced from and parallel to the first plane (E1), a first side wall (34) which extends from the first mounting flange (32) to the bottom wall (35) and encloses a first angle (al) with the first plane (E1) on an inner side of the cover, and a second side wall (36) which extends from the second mounting flange (38) to the bottom wall (35) and encloses a second angle (a2) with the first plane (E1) on an inner side of the cover. In order to allow a controlled deformation of the housing upon deployment of the airbag, both the first angle (al) and the second angle (a2) are acute angles between 30° and 60°, preferably between 40° and 45°, in particular 45° (Fig. 3).

Description

[0001] The present invention relates to an airbag module suitable for installation on the roof of a vehicle, a housing component for such an airbag module, and a vehicle including such an airbag module.

[0002] The first airbag module introduced into automotive technology was the front airbag module, which is used to protect the driver or front-seat passenger in the event of a basic frontal collision. Traditionally, such airbag modules were located inside the steering wheel (driver's front airbag module) or in the dashboard (passenger's front airbag module).

[0003] The updated concept proposes moving the front airbag module from the steering wheel / dashboard to a location between the vehicle's roof and headliner.

[0004] US 6,588,793B2 discloses such an airbag module and a vehicle including such an airbag module. The airbag module includes a housing, an airbag cushion, and an inflator. The housing has an upper portion and a lower portion. The lower portion shows a mounting flange, sidewalls extending from the mounting flange, and a bottom wall extending between the sidewalls. The housing is quite rigid, such that it does not deform substantially when the airbag cushion deploys.

[0005] DE 20 2014 003 779 U1 illustrates another concept. Here, only one housing component is provided, and the packaged airbag cushion is located between this housing component and the vehicle roof. The housing component is attached to the vehicle roof at its rear end and at its front end via two snap-fit ​​connectors. The housing component has no sidewalls, meaning that the cover for the airbag cushion, defined by the front section of the housing and the roof, is open at its sides. The middle section of the front section of the housing component curves towards the roof, so that the outer surface of the housing component appears as a groove. This grooved section is spaced at a distance from the headliner and the sunshade attached to the headliner. Therefore, when the airbag deploys, the grooved section can deform outward without interfering with the headliner and sunshade. This airbag module is relatively lightweight, but has the disadvantage that additional measures must be taken to ensure that no part of the airbag cushion leaves the cover defined by the housing component and the vehicle roof at the sides of the cover when the airbag cushion deploys.

[0006] Based on the prior art, the objective of this invention is to provide an airbag module suitable for installation on the roof of a vehicle, wherein at least one housing component is lightweight, ensuring reproducible deployment behavior of the airbag cushion, and not interfering with the headliner and / or sunshade when the airbag deploys.

[0007] This task is accomplished by the airbag module of the present invention. The present invention provides a housing component for such an airbag module and a vehicle including such an airbag module.

[0008] The airbag module of the present invention includes an airbag cushion, an inflator in fluid communication with the airbag cushion, and a housing component. The housing component includes a front section defining a portion of a cover for the airbag cushion when mounted to the roof of a vehicle, as known from DE 20 2014 003 779 U1. Compared to the airbag module described in that document, the front section of the airbag module of the present invention includes a first mounting flange and a second mounting flange located in a first plane; a first sidewall extending from the first mounting flange; and a second sidewall extending from the second mounting flange. Through these sidewalls, the cover for the airbag cushion is laterally closed, thereby securely preventing a portion of the airbag cushion from laterally deploying from the housing component. The first sidewall forms a first angle with the first plane on the inner side of the cover, and the second sidewall forms a second angle with the first plane on the inner side of the cover. The bottom wall, located in the second plane that is remote from and parallel to the first plane, extends between the two side walls. Both the first angle and the second angle are acute angles between 30° and 60°.

[0009] Due to this shape, the sidewall and the bottom wall deform together, resulting in the housing component deforming reproducibly in a direction perpendicular to the first and second planes (typically the vertical direction) with a relatively small "stroke". Furthermore, this "joint deformation" dissipates enough energy to safely prevent the housing component from detaching from its attached component (typically the roof).

[0010] Although the airbag module of the present invention can be substantially as lightweight as the airbag module described in DE 20 2014 003 779 U1, it provides a cover for the airbag that is open only at the front of the airbag module, thereby ensuring proper deployment of the airbag cushion.

[0011] When the airbag deploys, the bottom and side walls typically deform in such a way that they form a continuous wall without bending that spans from the first mounting flange to the second mounting flange. This continuous wall typically has a substantially uniform curvature.

[0012] To ensure a uniform force distribution when the airbag deploys, the front section is preferably mirror-symmetrical about at least one plane perpendicular to the first and second planes, and preferably the two planes are mirror-symmetrical.

[0013] In a preferred embodiment, the housing component further includes an inflator section extending from the rear end of the front section. To allow unimpeded deformation of the front section, the inflator section is preferably connected only to the bottom wall and not to the side walls. In this case, the inflator section preferably includes a rear wall and a third mounting flange for secure mounting of the inflator section. The inflator is preferably mounted to the rear wall of the inflator section; it can also be mounted to the roof of the vehicle. To facilitate the manufacturing process of the housing component, the housing component may be, for example, a stamped and bent sheet of metal. In some embodiments, it is preferred that the third mounting flange is not directly connected to the first and second mounting flanges. In other embodiments, it is preferable that the third mounting flange is connected to the first and second mounting flanges, such that a combined U-shaped mounting flange is first provided, wherein the first, second, and third mounting flanges are segments of the combined mounting flange. This can enhance the overall rigidity of the housing component.

[0014] Since the roof of a vehicle is usually flat, the third flange is usually located in the first plane.

[0015] Typically, all mounting flanges have an elliptical shape such that their length exceeds their width, and the length of the third mounting flange extends perpendicularly to the lengths of the first and second mounting flanges.

[0016] Preferably, the housing component is a single piece. This feature allows for safe and reproducible deformation without the risk of breakage. Furthermore, single-piece housing components are lightweight and easy to manufacture. Of course, the housing can also be made from more than one piece, for example, in a manner that includes more than one layer or by welding several pieces together.

[0017] The preferred material for the housing components is metal, particularly steel. In this case, the metal sheets used to make the housing components typically have a thickness between 1 mm and 2.5 mm.

[0018] Alternatively, the housing components can be made of plastic material. In this case, the housing components can be specifically cut to form a housing component shape similar to that of a housing component made of metal sheet. Of course, since a high-strength material (capable of withstanding high retraction forces) is required, it is preferable that the cut be made of fabric.

[0019] In the installed state, the airbag module is mounted to the roof via its mounting flange, such that at least a portion of the airbag cushion lies between the bottom wall and a section of the roof. The mounting flange may directly contact the roof, or a relatively thin additional layer may be located between the housing component and the roof. Since this layer does not need to withstand significant forces, it can be made from virtually any material, including flexible materials such as foil or strip fabric. This layer helps hold the airbag pack in place during the installation process.

[0020] When installed, the airbag module is typically covered by the roof liner.

[0021] The invention will now be described in detail with reference to the accompanying drawings and preferred embodiments.

[0022] The attached diagram shows:

[0023] Figure 1 This is a schematic cross-sectional view of a plane extending vertically and passing through the upper part of the vehicle, including the airbag module, according to one embodiment of the present invention.

[0024] Figure 2 It shows Figure 1 The content shown, but the section is far away. Figure 1 The cross-section thus allows the airbag module to be seen from the side.

[0025] Figure 3 It shows along Figure 1 The cross-sectional view taken from plane AA in the middle.

[0026] Figure 4 This shows what happens after the inflator has been triggered, causing the airbag cushion to deploy. Figure 1 The content shown in the image,

[0027] Figure 5 According to Figure 3 The representation shows Figure 4 The content shown means along Figure 4 The cross-sectional view taken from plane CC in the image, and

[0028] Figure 6 According to Figure 3 The representation shows Figures 1 to 5 Variations of the implementation scheme shown.

[0029] Figures 1 to 3 The diagram schematically illustrates the front of the vehicle roof R, a portion of the vehicle's windshield W, a portion of the vehicle's headliner C, and an airbag module 10 attached to the roof R and positioned between the roof R and the headliner C. In this document, Figure 3 It is along Figure 1The cross-sectional view taken from plane AA in the middle. Figure 1 It is along Figure 3 The cross-sectional view taken from plane BB in the middle, and Figure 2 The airbag module is shown in a side plan view.

[0030] Aside from fastening devices such as screws, the airbag module 10 consists of only three components: the shell component 20, the inflator 50, and the airbag pack. The airbag pack includes a folded and / or rolled-up airbag pad 55 and may also include a packaging (not shown). In the illustrated embodiment, and preferably, the shell component 20 is a single piece and preferably a stamped and bent sheet metal component. In this case, the sheet metal typically has a thickness between 1.5 mm and 2.5 mm. In an alternative embodiment, the shell component 20 may also be made of a plastic material, such as plastic fabric. Importantly, when the shell component 20 is made of a plastic material, the plastic material is not too rigid, allowing it to deform to some extent without breaking.

[0031] The housing component 20 can be viewed as having a front section 30 and an inflator section 40. In the installation configuration shown in the figure, the inflator section 40 is located behind the front section 30 (relative to the vehicle's longitudinal direction (X direction)). Specifically, as shown by... Figure 3 As can be seen, the front section 30, viewed along the transverse direction (Y direction) of the vehicle, has a first mounting flange 32, a first sidewall 34, a bottom wall 35, a second sidewall 36, and a second mounting flange 38. The lengths of the two mounting flanges 32 and 36 in the X direction exceed their widths in the Y direction, and they extend parallel to each other in the X direction. The mounting surfaces of the two mounting flanges 32 and 38 are connected to the roof R, and the mounting flanges 32 and 36 lie in a first plane E1 defined substantially by the roof R of the vehicle. The sidewalls 34 and 36 extend downward at an angle from these mounting flanges 32 and 38, such that the first sidewall 34 forms a first angle α1 with the first plane E1, and the second sidewall 36 forms a second angle α2 with the first plane E1. These two angles α1 and α2 are "interior angles," meaning that these two angles face each other. Preferably, at least the front section 30 of the housing component 20 is mirror-symmetric, such that these two angles α1 and α2 are identical. In each case, both angles α1 and α2 are acute angles, meaning they are less than 90°. Preferably, these angles are between 40° and 50°, particularly 45°. The bottom wall 35 extends between the two side walls and lies in a second plane E2 that is parallel to but, of course, far from the first plane E1. As can be seen in the figure, the second plane E2 is slightly away from the ceiling lining.

[0032] The inflator section 40 includes its own flange, namely the third mounting flange 42, and the rear wall 44 extends from the third mounting flange 42 to the bottom wall 35. The inflator 50 is connected to the rear wall, for example, by bolts. The length of the third mounting flange in the Y direction exceeds its width in the X direction, and (in their respective length directions) the third mounting flange 42 extends perpendicular to the first mounting flange 32 and the second mounting flange 38.

[0033] The third mounting flange 42 is not connected to the first mounting flange 32 and the second mounting flange 38, and the rear wall 44 is not connected to the side walls 34, 36, such that there are two lateral free spaces F between the inflator section 40 and the front section, as shown below. Figure 2 As can be seen, since the mounting flange does not deform or move during airbag deployment, the third mounting flange 42 can be connected to the first mounting flange 32 and the second mounting flange 38 to enhance the overall rigidity of the housing components, thereby reducing the force transmitted to the vehicle roof.

[0034] When the inflator 50 is triggered, the airbag cushion 55 deploys from the cover defined by the housing component 20 and the roof R. During inflation, the airbag cushion exerts a force on the front section of the housing component 20, and due to the described geometry, the front section deforms uniformly, resulting in a substantially uniform curvature between the first mounting flange 32 and the second mounting flange 38, as... Figure 5 As shown in the diagram. In this state, there is no longer a boundary between the sidewalls and the bottom wall. Due to this deformation, energy is dissipated, allowing the attachment of the shell components to the roof and the shell components themselves to remain intact. Additionally, the extension toward the roof liner in the vertical direction (Z direction) is relatively small, resulting in a small gap between the bottom wall and the roof liner in the stationary state (see, for example, [reference needed]). Figure 1 and Figure 2 This is sufficient to prevent the shell components from impacting the roof liner C when the airbag deploys.

[0035] exist Figures 1 to 5 In the illustrated embodiment, a section of the roof R directly forms the upper housing wall. Alternatively, an additional layer 22 may be provided between the roof R and the airbag pack. Since this additional layer 22 is supported by the roof R, it can be made of virtually any material. This additional layer can help ensure that the airbag pad 55 does not shift during installation.

[0036] List of reference numerals

[0037] 10 airbag modules

[0038] 20 housing components

[0039] 22 additional layers

[0040] 30 Front section of housing component

[0041] 32 First mounting flange

[0042] 34 First sidewall

[0043] 35 bottom wall

[0044] 36 Second sidewall

[0045] 38 Second mounting flange

[0046] 39 Continuous Wall

[0047] 40 air inflator section

[0048] 44 posterior wall

[0049] 42 Third mounting flange

[0050] 50 air inflator

[0051] 55 airbag cushion

[0052] C. Ceiling Lining

[0053] F Free Space

[0054] R roof

[0055] W windshield

Claims

1. An airbag module (10) suitable for installation on the roof (R) of a vehicle, the airbag module (10) comprising: Airbag cushion (55) Inflator (50), which is in fluid communication with the airbag cushion (55), and Housing component (20) The housing component (20) includes a front section (30) that, when mounted to the roof (R) of a vehicle, defines a portion of a cover for the airbag cushion (55). The front section (30) includes: A first mounting flange (32) and a second mounting flange (38) are located in a first plane (E1). The bottom wall (35) is located in a second plane (E2) that is remote from and parallel to the first plane (E1). A first sidewall (34) extends from the first mounting flange (32) to the bottom wall (35) and forms a first angle (α1) with the first plane (E1) on the inner side of the cover. The second sidewall (36) extends from the second mounting flange (38) to the bottom wall (35) and forms a second angle (α2) with the first plane (E1) on the inner side of the cover. The first angle α1 and the second angle α2 are both acute angles between 30° and 60°. The housing component (20) also includes an inflator section (40) extending from the rear end of the front section (30). The inflator section (40) includes a rear wall (44) and a third mounting flange (42). All mounting flanges (32, 38, 42) have a length exceeding their width, wherein the length of the third mounting flange (42) extends perpendicular to the length of the first mounting flange (32) and the length of the second mounting flange (38).

2. The airbag module according to claim 1, characterized in that, When the airbag cushion (55) deploys, the bottom wall (35) and the side walls (34, 36) deform in such a way that a continuous wall (39) is formed from the first mounting flange (32) to the second mounting flange (38), the continuous wall (39) having a substantially uniform curvature.

3. The airbag module according to claim 1 or claim 2, characterized in that, The front section (30) is mirror-symmetric about a plane perpendicular to the first plane (E1) and the second plane (E2).

4. The airbag module according to claim 1, characterized in that, The third mounting flange (42) is located in the first plane (E1).

5. The airbag module according to claim 1, characterized in that, The housing component (20) is a single piece.

6. The airbag module according to claim 5, characterized in that, The housing component (20) is made of metal sheet.

7. The airbag module according to claim 5, characterized in that, The housing component (20) is made of plastic material.

8. The airbag module according to claim 1, characterized in that, Both the first angle α1 and the second angle α2 are between 40° and 45°.

9. The airbag module according to claim 6, characterized in that, The metal sheet has a thickness between 1.5 mm and 2.5 mm.

10. A housing component (20) for an airbag module (10) according to any one of claims 1 to 9.

11. A vehicle comprising a roof (R) and an airbag module (10) according to any one of claims 1 to 9, the airbag module being mounted to the roof (R) via its mounting flanges (32, 38, 42) such that at least a portion of the airbag cushion (55) is located between the bottom wall (35) and a section of the roof (R).

12. The vehicle according to claim 11, characterized in that, The airbag module (10) is covered by the canopy liner (C).

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