Mounting bracket for curtain airbag

Abstract

A mounting bracket (220) for a curtain airbag includes a mounting plate (222, 224) configured to be mounted in a mounting tab (200) of the curtain airbag. The mounting plate includes an opening for receiving a fastener. The mounting bracket also includes a deployment plate configured to be mounted between folded portions of the curtain airbag and maintain a folded configuration of the folded portions. The mounting bracket also includes an arm portion (226) connecting the deployment plate to the mounting plate and maintaining the deployment plate spaced apart from the mounting plate in a predetermined orientation relative to the mounting plate. The mounting bracket also includes a slot (240) defined between the mounting plate and the deployment plate and having open ends adjacent the corresponding lateral edges of the mounting plate and the deployment plate. The arm portion defines a closed end of the slot opposite the open end.

Description

Technical Field

[0001] The present disclosure relates to an inflatable device for assisting in protecting vehicle occupants in the event of a side collision of a vehicle and / or a vehicle rollover. More specifically, the present disclosure relates to a mounting bracket for a curtain airbag. Background Art

[0002] It is known to inflate inflatable vehicle occupant protection devices to assist in protecting vehicle occupants. A particular type of inflatable vehicle occupant protection device is a curtain airbag. In response to a side collision of a vehicle and / or a vehicle rollover, the curtain airbag can be inflated to be away from the roof of the vehicle between the vehicle occupants and the side structure of the vehicle. Known curtain airbags are inflated from a deflated state using inflation fluid directed from an inflator to the curtain airbag.

[0003] When installed in a vehicle, the curtain airbag can be connected to the vehicle via mounting tabs extending from an edge of the curtain airbag, such as an upper edge. The curtain airbag is connected to the vehicle via fasteners that extend through the mounting tabs into the vehicle structure, such as a roof rail. When deployed, the curtain airbag covers the side structure along the length of the vehicle, including the door / doorframe, window opening, and pillars (A-pillar, B-pillar, C-pillar, etc.).

[0004] For a curtain airbag, it is important to avoid obstruction from structures such as roof rails and trim on pillars so that the curtain airbag can be properly inflated and deployed. To this end, the curtain airbag can be placed in a stored state by rolling up and / or folding it in a specific manner configured to avoid these structures. Summary of the Invention

[0005] A mounting bracket for a curtain airbag includes a mounting plate configured to be mounted in a mounting tab of the curtain airbag. The mounting plate includes an opening for receiving a fastener. The mounting bracket further includes a deployment plate configured to be mounted between folded portions of the curtain airbag and maintain the folded configuration of the folded portions. The mounting bracket further includes an arm portion that connects the deployment plate to the mounting plate and maintains the deployment plate spaced apart from the mounting plate in a predetermined orientation relative to the mounting plate. The mounting bracket further includes a slot defined between the mounting plate and the deployment plate and having open ends adjacent corresponding lateral edges of the mounting plate and the deployment plate. The arm portion defines a closed end of the slot opposite the open ends.

[0006] According to one aspect, the arm portion can extend between and connect the lateral edges of the mounting plate and the deployment plate, opposite the open ends of the slot.

[0007] According to another aspect, the deployment plate may include an opening for receiving a fastener. The mounting bracket has a reversible configuration, where the identity of the mounting plate and the deployment plate is determined by which of these plates is mounted on the mounting tongue.

[0008] According to another aspect, the mounting bracket and the deployment bracket may have the same configuration.

[0009] According to another aspect, the arm portion is configured to control the angle and orientation of the deployment plate relative to the mounting plate.

[0010] According to another aspect, the arm portion may be configured to allow adjustment of the angle and orientation of the deployment plate relative to the mounting plate to accommodate changing vehicle architectures.

[0011] According to another aspect, the deployment plate may be configured to be positioned outside of the curtain airbag when the mounting plate is mounted on the mounting tongue.

[0012] According to another aspect, when the mounting plate is mounted on the mounting tongue, the lower portion of the mounting tongue is received in the slot.

[0013] According to another aspect, the airbag module may include a curtain airbag that can be inflated away from the vehicle's roof to a deployment position between the vehicle's side structure and the vehicle occupant. The airbag module may also include an inflator that can be actuated to supply inflation fluid to the curtain airbag to inflate and deploy the airbag. The airbag module may also include a mounting bracket. The curtain airbag may include a mounting tongue that includes a sleeve configured to receive the mounting plate of the mounting bracket.

[0014] According to another aspect, the mounting tongue may include stacked panels, and the sleeve is defined between the stacked panels. The mounting plate may be positioned in the sleeve, where the curtain airbag material is positioned in the slot, and the deployment plate is positioned outside of the sleeve on the outer side of the curtain airbag.

[0015] According to another aspect, the curtain airbag may have a stored state, in which the upper portion of the airbag includes a flip-fold. The first portion of the flip-fold may be positioned adjacent to the upper surface of the deployment plate. The second portion of the flip-fold may be positioned adjacent to the lower surface of the mounting plate. The fold of the flip-fold may extend around the terminal edge of the deployment plate.

[0016] According to another aspect, the curtain airbag in the stored state includes a lower portion adjacent to the upper portion of the flip-fold, and the lower portion is rolled up. The lower portion may be rolled up in the outer direction.

[0017] According to another aspect, the curtain airbag is configured such that the mounting lugs and the mounting brackets are positioned adjacent to a vehicle structure that is desired to be avoided during curtain airbag deployment. According to another aspect, the vehicle structure can be one or more trim pieces of the vehicle. According to another aspect, the one or more trim pieces can be pillar trim pieces and / or roof rail trim pieces.

[0018] According to another aspect, the deployment plate can be configured to maintain the upper portion of the curtain airbag in a flip-folded state in the stored state of the curtain airbag. The upper portion can be configured to deploy in a direction that keeps the curtain airbag from engaging with one or more trim pieces.

[0019] According to another aspect, the flip-folded portion of the curtain airbag can include a first portion positioned adjacent to the upper surface of the deployment plate, a second portion positioned adjacent to the lower surface mounting plate, and a fold extending around the terminal edge of the deployment plate. According to another aspect, the curtain airbag in the stored state can include a lower portion adjacent to the flip-folded upper portion, with the lower portion rolled up. According to another aspect, the lower portion can be rolled up in an outward direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The foregoing and other features of the present disclosure will become apparent to those skilled in the art to which the present disclosure pertains upon consideration of the following description with reference to the accompanying drawings, in which:

[0021] Figure 1 is a schematic view of an apparatus for assisting in protecting vehicle occupants according to the present invention, illustrating the apparatus in a deflated and stored state in a vehicle.

[0022] Figure 2 is Figure 1 a schematic view of the apparatus in an inflated state in a vehicle.

[0023] Figure 3 is a cross-sectional view taken generally along Figure 2 centerline 3-3.

[0024] Figure 4 is a cross-sectional view taken generally along Figure 1 line 4-4 in

[0025] Figure 5 is a cross-sectional view taken generally along Figure 2 centerline 5-5.

[0026] FIG. 6A is a perspective view illustrating a mounting bracket portion of the apparatus.

[0027] FIG. 6B is a front view of the mounting bracket of FIG. 6A.

[0028] FIG. 6C is a side view of the mounting bracket of FIG. 6A.

[0029] Figure 7 This is a front view showing the installation of the mounting bracket in the mounting tongue of the curtain airbag.

[0030] Figure 8 This is a partial cross-sectional side view showing the mounting bracket installed in the mounting tongue of the curtain airbag. DETAILED DESCRIPTION

[0031] In Figure 1 and Figure 2 an example configuration of a device 10 for assisting in protecting an occupant of a vehicle 12 is shown. The device 10 includes an inflatable vehicle occupant protection device in the form of a curtain airbag 14 that is mounted adjacent to a side structure 16 of the vehicle 12 and the vehicle's roof 18 by a series of fasteners 22 spaced along its length. The side structure 16 of the vehicle 12 includes an A-pillar 30, a B-pillar 32, a C-pillar 34, and a front side window 40 and a rear side window 42. The vehicle 12 also includes a front vehicle seat 44 positioned adjacent to the front side window 40 and a rear vehicle seat 46 positioned adjacent to the rear side window 42. This configuration is provided only as an example. The vehicle 12 can have any configuration in which a curtain airbag is implemented.

[0032] An inflator 24 is fluidly connected to the curtain airbag 14. The inflator 24 contains a stored quantity of pressurized inflation fluid in the form of a gas for inflating the curtain airbag 14. The inflator 24 alternatively contains a combination of a pressurized inflation fluid and a combustible material for heating the inflation fluid, or can be a pyrotechnic inflator that uses the combustion of a gas-generating material to generate the inflation fluid. As another alternative, the inflator 24 can have any suitable type or construction for supplying a medium for inflating the curtain airbag 14.

[0033] The device 10 also includes a cover 26 ( Figure 1 ), such as a woven or non-woven fabric sheath, that encapsulates and helps support the curtain airbag 14 in its stored and deflated state. The deflated curtain airbag 14 and the cover 26 have an elongated configuration and extend along the vehicle roof 18 and along the side structure 16 of the vehicle 12 above the side windows 40 and 42. The curtain airbag 14 encapsulated in the cover 26 and the inflator 24 together form an airbag module 150 that can be installed in the vehicle as a unit. To facilitate this installation, the airbag module 150 can be connected to the vehicle 12 at mounting tongues 200 spaced along an upper edge portion 70 of the curtain airbag 14.

[0034] The curtain airbag 14 ( Figure 3)(including panels 50 and 52 of materials arranged in a stacked manner. The overlapping portions of panels 50 and 52 are interconnected along at least a part of the perimeter 54 of the curtain airbag 14 to form a perimeter connection portion 56 of the curtain. The perimeter connection portion 56 helps to define the inflatable volume of the curtain airbag 14. The curtain airbag 14 may also include an internal connection portion (not shown), where the stacked panels 50 and 52 are interconnected within the perimeter 54 to form a non-inflatable portion that helps to define the inflatable chamber of the curtain. In the installed state of the airbag module 150, panel 50 is the outermost-facing panel of the curtain airbag 14.)

[0035] The curtain airbag 14 can be formed in a variety of ways, such as by weaving the stacked panels 50 and 52 into a single-piece woven (OPW) construction, where yarns (such as nylon or polyester yarns) are woven simultaneously to form one-layer and two-layer portions of the airbag. The curtain airbag 14 can alternatively be formed from separately woven panels interconnected, for example, by stitching, ultrasonic welding, thermal bonding, or adhesives. The curtain airbag 14 can be coated with an air-impermeable material, such as polyurethane, or laminated with an air-impermeable film. Thus, the curtain airbag 14 can have a substantially airtight construction. Those skilled in the art will appreciate that alternative materials (such as polyester yarns) and alternative coatings (such as silicone) can also be used to construct the curtain airbag 14.)

[0036] The perimeter 54 of the curtain airbag 14 is at least partially defined by an upper edge 70 of the curtain, an opposite lower edge 72, and front portions 74 and rear portions 76 of the curtain airbag that are horizontally spaced apart along the upper edge and the lower edge, respectively. The front portions 74 and rear portions 76 of the curtain airbag 14 include front edges 80 and rear edges 82 that are horizontally spaced apart along the upper edge 70 and the lower edge 72 and extend between the upper edge and the lower edge. Of course, the shape and size of the curtain airbag 14 can vary depending on factors such as the vehicle's architecture and the desired coverage area of the airbag.)

[0037] In the event of an event where occupant protection is desired, the airbag controller 350 actuates the inflator 24 via the lead wire 352. The inflator 24 supplies inflation fluid to the inflatable volume of the curtain airbag 14 to inflate and deploy the curtain airbag from a stored state (see Figure 1 and Figure 4 ) to a deployed state (see Figure 2 , Figure 3 and Figure 5 ). The curtain airbag 14 deploys in a generally downward direction away from the roof 18 and becomes positioned between the side structure 16 of the vehicle and the occupant(s) 13 of the vehicle seat. In the example configuration illustrated in the figures, the curtain airbag 14, when in the deployed state, covers a portion of the side structure 16 that includes portions of the A-pillar 30, B-pillar 32, and C-pillar 34 of the vehicle 12 and can help protect the occupant from impacts with the side structure and / or the pillars.)

[0038] Those skilled in the art will appreciate that the scope and coverage area of the curtain airbag 14 in the vehicle 12 can vary. For example, the scope and coverage area of the curtain airbag 14 can vary according to various factors, such as the architecture of the vehicle 12, the position of the curtain airbag in the vehicle, and the desired scope or coverage area of the curtain airbag. The disclosure herein is not limited to any particular curtain airbag or airbag module and can be applied to any curtain airbag or airbag module configuration.

[0039] The airbag module 150 is fixed to the vehicle on or near the roof rail 100, which is formed at the intersection of the side structure 16 and the roof 18. Refer to Figure 4 and Figure 5 , the side structure 16, the roof 18, and the roof rail 100 are formed of metal sheets that are connected (i.e., welded) to form the architecture of the vehicle 12. Figure 4 and Figure 5 The portion of the side structure 16 shown in Figure 4 and Figure 5 includes the B-pillar 32 of the vehicle 12. Although Figure 4 and Figure 5 are merely schematic diagrams showing non-limiting example configurations, it can be seen that the side structure 16, the roof 18, the B-pillar 32, and the roof rail 100 are formed by a number of panels 102, 104, 106. The airbag module 150 is connected to a panel of the roof rail 100 that extends at an angle between the side structure 16 and the roof 18 in a recess 108 defined by the metal sheets 102, 106 at the upper end of the B-pillar 32.

[0040] As shown, in the stored, pre-deployment state, the airbag module 150 is hidden by a combination of structures including the roof lining 300, the roof rail trim 304, and the B-pillar trim 310. When the curtain airbag 14 inflates and deploys, it must displace some or all of these structures in order to reach the deployment position within the necessary time frame.

[0041] When displacing these structures, competing factors come into play. On the one hand, it is important that the curtain airbag inflates and deploys as closely as possible along the side structure 16, due to the limited space between the side structure and the adjacent occupant, as the occupant is positioned near this structure. On the other hand, it is important that the inflating / deploying curtain airbag is not obstructed by the roof lining 300 and the trims 304, 310 such that it does not get stuck or damaged during deployment. The main concern among these concerns is engaging the B-pillar trim 310. If the curtain airbag 14 gets stuck on the upper end of the trim 310, it may be damaged and lose pressure. It may also get stuck by the trim 310 and be inhibited from achieving full deployment within the necessary amount of time.

[0042] Avoiding these structures would suggest deploying the curtain airbag 14 along a more medial trajectory, but this conflicts with the competing interest of deploying the airbag closer to the side structure 16. To balance these two interests, the curtain airbag 14 is configured to have a stowed configuration in which the airbag is rolled up and folded such that an initial deployment movement is made unimpeded by the trim; a subsequent deployment movement causes the airbag to follow along the side structure 16.

[0043] The airbag module 150 includes a mounting bracket 220 that cooperates with a mounting tab 200 to secure the curtain airbag 14 to the vehicle 12 via a fastener 22. Advantageously, the mounting bracket 220 is configured to help maintain the curtain airbag 14 in a rolled / folded state that is configured to produce the deployment characteristics described in the previous paragraph. When the curtain airbag 14 is encapsulated within the airbag module 150 and hidden by the headliner 300 and trim 304, 310, the mounting bracket 220 helps maintain this rolled / folded state of the curtain airbag 14. This helps encapsulate the curtain airbag 14 within the airbag module 150 such that the module is configured as a unit ready for installation that only needs to be fastened to the vehicle 12 via the mounting tab 200 in which the mounting bracket 220 is installed.

[0044] Referring to FIG. 6, the mounting bracket 220 includes a first bracket plate 222 and a second bracket plate 224 interconnected by an arm portion 226, respectively. The mounting bracket 220 may be bent or otherwise formed with a bend 230 in the arm portion 226 that causes the bracket plates 222, 224 to extend relative to each other at an angle generally indicated by A. In the drawings, the angle A is shown as being approximately 90 degrees. However, depending on factors such as the vehicle architecture and the orientation of the airbag module 150 when installed in the vehicle 12, the angle A may vary. By way of example, this is shown in FIG. 6C in dashed lines, which shows various angles at which the first bracket plate 222 and the second bracket plate 224 may extend based on the bend 230 in the arm portion 226.

[0045] The first bracket plate 222 and the second bracket plate 224 each have a generally planar rectangular configuration with rounded corners. The arm portion 226 spaces the bracket plates 222, 224, forming a slot 240 that extends between the bracket plates. The arm portion 226 is spaced from at least one lateral edge of the bracket plates 222, 224 such that the slot 240 has an open end 246. In the example configuration illustrated in the drawings, the arm portion 226 extends between the aligned lateral edges 232, 234 of the bracket plates 222, 224 and forms an adjacent edge of the mounting bracket 220. Thus, the slot 240 extends the width of the bracket plates 222, 224 minus the width of the arm portion 226.

[0046] The first support plate 222 and the second support plate 224 each include a centrally located fastener opening 242 configured to receive a fastener, such as a bolt or a screw, for securing the bracket 220 and the airbag module 150 to the vehicle 12. Each fastener opening 242 has a generally circular configuration and may include slots 244 extending radially from the opening. In the example configuration illustrated in the figures, the fastener opening 242 includes four slots 244 that extend in radially spaced directions 90 degrees apart.

[0047] The slots 244 allow the fastener opening 242 to have a diameter configured to interfere with the large diameter of the threaded shank portion of the threaded fastener such that the fastener can be held in the opening due to the interference fit. The slots 244 allow portions of the bracket material between the slots to deflect to facilitate the installation of the threaded fastener in the fastener opening 242. This deflection and the resulting interference can hold the fastener 22 in the fastener opening 242 prior to and during the installation of the airbag module 150.

[0048] In some cases, the slots 244 are not necessary and may not be included. For example, the slots 244 can be omitted and a retaining washer can be installed on the fastener shank on the outer side of the mounting tab 200. As another example, the slots 244 can be omitted where the fasteners are not shipped with the airbag module 150 assembly but are added at the vehicle assembly plant.

[0049] The mounting bracket 220 has a high-strength construction that can be produced using a variety of materials. For example, the mounting bracket 220 can be formed from high-strength nylon plastic, high-density polyethylene (HDPE), polypropylene (PP), or thermoplastic olefin (TPO). In such a construction, the mounting bracket can have a molded construction such that the support plates 222, 224, and the arm portion 226 can be formed as a single-piece component, which can improve the strength and integrity of the structure. The fastener openings 242 and the slots 244 (if included) can be formed as part of the molding or in a separate step (e.g., a stamping or punching step) after forming the support plates 222, 224, and the arm portion 226.

[0050] In another configuration, the mounting bracket 220 may have a metal (e.g., steel) construction, where the bracket plates 222, 224, and the arm portion 226 may be stamped from a single sheet of metal and then bent to form the mounting bracket 220 as a single-piece component. In this configuration, the fastener openings 242 and the slots 244 (if included) may be formed together with the bracket plates 222, 224, and the arm portion 226 in a single stamping step or in one or more separate stamping steps. If the angle A between the bracket plates 222, 224 was originally intended to be adjustable, this construction may be beneficial because it would require only a simple bending of the arm portion 226.

[0051] Reference Figure 7 , the curtain airbag 14 is configured to have a pit or sleeve 202 in the region of the mounting lug 200. The sleeve 202 is located between the stacked airbag panels 50, 52, in the region of the curtain airbag 14 that includes the mounting lug 200 and in a portion of the airbag at the upper edge 70. The sleeve 202 is configured to receive the mounting bracket 220. Alternatively, the mounting lug 200 may be configured with a pit, in which case one end of the sleeve 202 is closed. Thus, the closed pit configuration of the mounting lug 200 would involve a closure at one of the ends of the sleeve 202 (such as the left or right side as shown in Figure 7 ), which is generally indicated by the dashed line at 208 in Figure 7 . These closures may be formed by the connection of the panels 50, 52, such as those discussed in the following paragraphs.

[0052] The sleeve 202 is partially defined by the connections 204, 206 of the panels 50, 52 around the sleeve 202. In the OPW configuration of the curtain airbag 14, the connections 204, 206 may be regions of a single layer of OPW material around the sleeve. In a configuration where the panels are separate and assembled together, the connections 204, 206 may be stitches or welds that interconnect the panels 50, 52. The region of the connection 204, 206 between the panels 50, 52, whether it is a single-layer OPW construction, a stitched construction, or a welded construction, is generally shown by the hatched region in Figure 7 . The width or thickness of the connections 204, 206 may be configured to be commensurate with the amount of stress the material experiences during airbag deployment and the material properties of the airbag panels 50, 52.

[0053] The mounting lug 200 includes a fastener opening 210 that extends through the two layers 50, 52 of the airbag material. The fastener opening 210 is configured to receive a fastener 22 at the location of the mounting lug 200, which connects the airbag module 150 to the vehicle 12. Thus, the fastener opening 210 is configured to align with the fastener opening 242 in the mounting bracket 220 when the bracket is installed in the sleeve 202.

[0054] The mounting bracket 220 is configured to be mounted in the sleeve 202 to reinforce the mounting lug 200 and facilitate the encapsulation and installation of the airbag module 150 in the vehicle 12. The mounting bracket 220 is inserted into the sleeve 202 between the layers 50, 52, as generally indicated by the arrow in Figure 7 . As Figure 7 shown, the mounting bracket 220 can have a reversible or ambidextrous configuration that allows the bracket to be mounted from either end of the mounting lug 200 (left or right as shown in the figure).

[0055] Figure 7 The ambidextrous left / right orientation in which the mounting bracket 220 can be installed is shown. During installation, the mounting bracket 220 and the curtain airbag 14 / mounting lug 200 are manipulated so that the bracket plates 222, 224 not positioned in the mounting lug are positioned behind the curtain airbag 14, i.e., on the outer side of the curtain airbag as observed in Figure 8 . For this purpose, the mounting lug 200 can be folded forward, i.e., as observed in Figure 7 , as generally indicated by the curved arrow in Figure 7 so as to be positioned to receive the bracket plates (plate 224 for left insertion, plate 222 for right insertion), while the other plate is positioned behind / outside the airbag 14. In Figure 7 , for clarity in the illustration, the mounting lug 200 is shown in an unfolded / flat state continuous with the curtain airbag 14, with the curved arrow indicating the folding of the lug for bracket installation.

[0056] As can be seen in Figure 7 , to mount the mounting bracket 220 from the right end of the mounting lug 200, the first bracket plate 222 is installed in the sleeve 202. When this is done, the first bracket plate 222 enters the slot 240, and the second bracket plate 224 is positioned outside the sleeve 202, adjacent to the panel 52, i.e., behind the curtain airbag 14 as observed in Figure 7 or on the outer side of the curtain airbag as observed in Figure 8 . Once inserted, the mounting bracket 220 is manipulated until the fastener opening 242 in the first bracket plate 222 is aligned with the fastener opening 210 in the mounting lug 200 (see Figure 8 ). In this installation, the fastener opening 242 in the second bracket plate 224 is not used.

[0057] To mount the mounting bracket 220 from the left end of the mounting lug 200, the bracket is flipped so that the second bracket plate 224 is installed in the sleeve 202. When this is done, the second bracket plate 224 enters the slot 240, and the first bracket plate 222 is positioned outside the sleeve 202, adjacent to the panel 52, i.e., as inFigure 7 As observed in, behind the curtain airbag 14 or as in Figure 8 As observed in, outside the curtain airbag. Once inserted, the mounting bracket 220 is manipulated until the fastener opening 242 in the second bracket plate 224 is aligned with the fastener opening 210 of the mounting lug 200 (see Figure 8 ). In this installation, the fastener opening 242 of the first bracket plate 222 is not used.

[0058] As can be appreciated from the foregoing, the bracket plate installed in the sleeve 202 serves as a mounting plate for the airbag module 150, while the other bracket plate serves as a deployment plate for helping to control the deployment trajectory of the curtain airbag in the vehicle 12. For clarity, when describing the mounting bracket 220 in this regard, reference will be made to the mounting plate 250 and the deployment plate 252. Referring to Figure 4 and Figure 8 , the first bracket plate 222 is the mounting plate 250, and the second bracket plate 224 is the deployment plate 252.

[0059] As previously mentioned, the deployment plate 252 helps to maintain the stored state of the curtain airbag 14 before deployment. As Figure 4 shown in, in the stored state, the curtain airbag 14 is both rolled up and folded. More specifically, in the stored state, the curtain airbag 14 is turned over and folded and rolled up. In Figure 4 , the turn-over fold is shown at 260, and the roll is shown at 280. The turn-over fold 260 is formed at the upper end of the curtain airbag 14, i.e., along the upper edge 70 of the airbag, and a roll 280 is formed below the turn-over fold by rolling up the airbag from the lower edge 72 until it reaches the turn-over fold.

[0060] The turn-over fold 260 is a back-and-forth fold, which can be referred to as a Z-fold. The turn-over fold 260 has three parts defined by two folds. The first part 262 of the turn-over fold 260 extends above and along the upper surface of the deployment plate 252 to the first fold 264, which wraps around the inner edge of the deployment plate. The second part 266 of the turn-over fold 260 extends along the lower surface of the deployment plate 252 to the second fold 270, which is positioned adjacent to or near the outer edge of the deployment plate. The third part 272 of the turn-over fold extends back along the second part 266 and marks the interface between the turn-over fold 260 and the roll 280.

[0061] To achieve the positioning of the deployment plate 252 between the first part 262 and the second part 266 of the turn-over fold 260, the mounting bracket 220 needs to be installed such that the deployment plate is positioned on the outer side (OB) of the curtain airbag 14, rather than the inner (IB) side of the curtain airbag. This requires Figure 7Carefully position and manipulate the mounting bracket 220 during the installation procedure shown. Specifically, as Figure 8 shown, the mounting lug 200 needs to be folded at or around the connection portion 206 such that when the mounting plate 250 is installed in the sleeve 202, the deployment plate 252 is positioned on the outer side OB of the curtain airbag 14, i.e., adjacent to the outer panel 52.

[0062] Figure 4 The roll 280 illustrated in is an outer roll, meaning that the roll is configured / constructed by initially rolling up the lower edge 72 of the curtain airbag 14 in a direction towards the outer side of the vehicle side structure 16, as observed in the installed state of the airbag module 150, i.e., as shown by the arrow A in Figure 4 . This creates an unwrapping movement towards the inside, i.e., away from the side structure 16, during deployment. Of course, Figure 4 the folded and rolled-up state of the curtain airbag shown in is not meant to be restrictive, as the deployment plate 252 can be used to help maintain alternative folded and / or rolled-up states of the curtain airbag 14.

[0063] Advantageously, the above-described rolled-up and folded configuration of the airbag 14 maintained by the mounting bracket 220 is configured to avoid interference from the trim during airbag deployment by controlling the deployment trajectory and position timing. The rolled-up and folded configuration of the airbag 14 can also help minimize interaction with the headliner 300, although some interaction is inevitable. The flip-fold 260 positioned along the upper edge 70 of the curtain airbag 14 is in the first part of the airbag to receive inflation fluid from the inflator 24. When this occurs, the flip-fold 260 unfolds. Due to the arrangement of the flip-fold 260, the unfolding of the curtain airbag 14 along the fold 264 causes the remaining part of the airbag below the fold (including the roll 280) to move along an inner trajectory during the early stages of the deployment event. This trajectory and timing control helps the curtain airbag 14 avoid interacting with the B-pillar trim 310.

[0064] After initially moving inwards, the rolled-up portion 280 begins to unwind in a direction opposite to the rolling-up direction. Observing Figure 4 , after initially being unobstructed by the trim 310, the roll 280 unwinds in an outer direction towards the side structure 16. This unwinding direction helps ensure that the trajectory of the deployed curtain airbag 14 follows along the side structure, close to or engaging with the trim 310. This helps ensure that the curtain airbag 14 inflates and fully deploys and pressurizes in sufficient time to help protect the occupants.

[0065] The mounting bracket 220, and in particular the deployment plate 252, helps to maintain the flip-fold along the upper edge 70 of the curtain airbag 14 during assembly and installation. Since the airbag module 150 is a soft package, this means that there is no rigid self-supporting structure along its length, such as a plastic housing, to maintain its shape. The only support is the fabric cover 26, which encapsulates the curtain airbag 14 but does not reinforce its rolled-up and flip-fold configuration. During installation, the soft cover 26 can bend, twist, and otherwise be manipulated, which can compromise the rolled-up and flip-fold configuration of the internal curtain airbag 14.

[0066] Advantageously, the mounting bracket 220 maintains and reinforces the flip-fold, especially at its most critical locations, such as adjacent pillar trims. In fact, the position and arrangement of the bracket 220 can be configured based on the specific architecture of the vehicle in which the airbag module 150 is installed, so as to avoid interference with airbag deployment from trims or any structure specific to that particular vehicle.

[0067] From the foregoing description of the present invention, those skilled in the art will recognize improvements, variations, and modifications. Such improvements, changes, and modifications within the scope of the art are intended to be covered by the appended claims.

[0068] The present invention has been described, and the following claims are claimed.

Claims

1. An installation bracket for a curtain airbag, comprising: An installation plate configured to be installed in an installation tab of a curtain airbag, the installation plate including an opening for receiving a fastener; A deployment plate configured to be installed between folded portions of the curtain airbag and maintain the folded configuration of the folded portions; And An arm portion that connects the deployment plate to the installation plate and maintains the deployment plate spaced apart from the installation plate in a predetermined orientation relative to the installation plate; And A slot defined between the installation plate and the deployment plate and having open ends adjacent corresponding lateral edges of the installation plate and the deployment plate, wherein the arm portion defines a closed end of the slot opposite the open ends.

2. The installation bracket according to claim 1, wherein, The arm portion extends and connects between lateral edges of the installation plate and the deployment plate, opposite the open ends of the slot.

3. The installation bracket according to claim 1, wherein, The deployment plate includes an opening for receiving a fastener, and the mounting bracket has a reversible configuration, wherein the identity of the installation plate and the deployment plate is determined by which of the plates is installed in the installation tab.

4. The installation bracket according to claim 3, wherein, The mounting bracket and the deployment bracket have the same configuration.

5. The installation bracket according to claim 1, wherein, The arm portion is configured to control the angle and orientation of the deployment plate relative to the installation plate.

6. The installation bracket according to claim 5, wherein, The arm portion is configured to allow adjustment of the angle and orientation of the deployment plate relative to the installation plate to accommodate changing vehicle architectures.

7. The installation bracket according to claim 1, wherein, When the installation plate is installed in the installation tab, the deployment plate is configured to be positioned outside the curtain airbag.

8. The installation bracket according to claim 1, wherein, When the installation plate is installed in the installation tab, a lower portion of the installation tab is received in the slot.

9. An airbag module, comprising: A curtain airbag inflatable from a vehicle roof away to a deployment position between a side structure of the vehicle and a vehicle occupant; An inflator actuable to supply inflation fluid to the curtain airbag to inflate and deploy the airbag; And The mounting bracket according to claim 1, wherein the curtain airbag includes an installation tab, the installation tab including a sleeve configured to receive the installation plate of the mounting bracket.

10. The airbag module according to claim 9, wherein, The installation tab includes stacked panels defining the sleeve therebetween, the installation plate is positioned in the sleeve, curtain airbag material is positioned in the slot, and the deployment plate is positioned outside the sleeve, on an outer side portion of the curtain airbag.

11. The airbag module according to claim 10, wherein, The curtain airbag has a stored state in which an upper portion of the airbag includes a flip-fold, wherein a first portion of the flip-fold is positioned adjacent an upper surface of the deployment plate, a second portion of the flip-fold is positioned adjacent a lower surface of the installation plate, and the fold of the flip-fold extends around a terminal edge of the deployment plate.

12. The airbag module according to claim 11, wherein, The curtain airbag in the stored state includes a lower portion adjacent an upper portion of the flip-fold, the lower portion being rolled up.

13. The airbag module according to claim 12, wherein, The lower portion is rolled up in an outer direction.

14. The airbag module according to claim 9, wherein, The curtain airbag is configured such that the installation tab and the mounting bracket are positioned adjacent a vehicle structure that is desired to be avoided during deployment of the curtain airbag.

15. The airbag module according to claim 14, wherein, The vehicle structure includes one or more trim parts of the vehicle.

16. The airbag module according to claim 15, wherein, The one or more trim parts include at least one of a pillar trim part and a roof rail trim part.

17. The airbag module according to claim 14, wherein, The deployment plate is configured to maintain an upper portion of the curtain airbag in a flipped and folded state in the stored state of the curtain airbag, wherein the upper portion is configured to deploy in a direction that avoids engagement of the curtain airbag with the one or more trim parts.

18. The airbag module according to claim 17, wherein, The flipped and folded portion of the curtain airbag includes a first portion positioned adjacent an upper surface of the deployment plate, a second portion mounted adjacent a lower surface mounting plate, and a fold extending around a terminal edge of the deployment plate.

19. The airbag module according to claim 18, wherein, The curtain airbag in the stored state includes a lower portion adjacent the upper portion of the flipped and folded portion, and the lower portion is rolled up.

20. The airbag module according to claim 19, wherein, The lower portion is rolled up in an outer lateral direction.

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