Curtain airbag with package maintenance structure

Abstract

An apparatus for assisting in protecting an occupant of a vehicle includes a curtain airbag (14) having an encapsulated state wherein the curtain airbag (14) is rolled up and / or folded to be mounted along a roof rail in the vehicle. A curtain airbag (14) is configured to inflate and deploy along a side structure of a vehicle structure. The curtain airbag (14) includes a channel (100) configured to receive a package maintenance structure (120) configured to reinforce a predetermined configuration of the curtain airbag (14) in a packaged state.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Patent Application Serial No. 18 / 453,625, filed August 22, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to a device for helping to protect vehicle occupants. More particularly, this invention relates to a device comprising a curtain airbag and a structure for maintaining a small package size. Background Technology

[0004] An inflatable vehicle occupant protection device, such as an airbag, is known to help protect vehicle occupants. The airbag can be deployed in response to events requiring occupant protection, such as a collision with the vehicle, a rollover, or a combination thereof. A particular type of airbag is an inflatable curtain airbag, which inflates between the vehicle occupants and the side structure of the vehicle in a direction away from the vehicle roof. Known curtain airbags inflate from a collapsed and stored state extending along the longitudinal beams of the vehicle roof at or near the intersection of the vehicle's side structure and roof. The curtain airbag is concealed by the vehicle's headliner and trim.

[0005] Curtain airbags can have various constructions. For example, a curtain airbag can have a cut-and-stitched construction, where the overlying panels are cut to size and interconnected by stitching to form a seam that defines an inflatable chamber between the panels and a non-inflatable portion outside the chamber. Alternatively, a curtain airbag can have a single-piece woven (OPW) construction, where the woven airbag structure has individual and simultaneous weaves to define portions or layers of inflatable chambers, with some interlacing to define single-layer seams and non-inflatable areas of the OPW curtain airbag. Stitches can be added after the airbag is woven into the OPW curtain airbag.

[0006] When an event requiring airbag inflation, such as a vehicle collision, is detected, a sensor signals the inflator. Upon receiving the signal from the sensor, the inflator is actuated and supplies inflation fluid to the airbag in a known manner. The inflating airbag exerts a force that causes concealed structures (such as headliners, trim pieces, padding, etc.) to rupture, tear, shift, or otherwise open, and the airbag inflates toward its fully inflated and deployed state. In this inflated and deployed state, the airbag helps protect vehicle occupants from impacts such as those involving vehicle components.

[0007] Curtain airbags are typically stored by rolling up and / or folding. However, rolling up is typically the primary method for placing curtain airbags in a sealed state, ready for installation in a vehicle. To facilitate rolling up / folding, a tool such as a thin rod or bar is placed on top of the curtain airbag or in a sleeve formed within the airbag. The curtain airbag is then rolled up / folded using the tool, so that the rolled-up / folded shape of the curtain airbag conforms to the shape of the tool. A wrapping or sleeve can then be placed around the rolled-up / folded curtain airbag to maintain the airbag in the rolled-up / folded state. The tool can then be removed, leaving the curtain airbag in a sealed state.

[0008] "Installation state" refers to a curtain airbag in a ready-to-install state, whether it is rolled up, folded, or a combination of both. In the installation state, the curtain airbag may also include additional features and / or structures, such as encapsulation sleeves and / or coverings, mounting and / or fastening structures (fasteners, clamps, brackets, etc.), and inflator components, such as inflators, filling tubes, diffusers, etc. The curtain airbag and these additional components together constitute what is known as airbag encapsulation or curtain airbag encapsulation, which is the ready-to-install component of a vehicle safety system.

[0009] When configuring curtain airbags for a specific vehicle architecture, care must be taken to ensure that the curtain airbag enclosure fits within the boundaries of the vehicle structure. These boundaries are typically defined by the vehicle's sheet metal structure (e.g., pillars (A, B, C, D pillars, etc.), roof, and roof longitudinal beams) and the interior trim that covers the enclosure once installed (e.g., headliner, pillar trim, and door trim). Similarly, the space provided by these structures determines the shape factor that the curtain airbag enclosure can take. Because space is extremely limited, minimizing the size of the curtain airbag enclosure is often crucial. While the necessary length of the curtain airbag is fixed to some extent (because it must cover a necessary portion of the vehicle's length), its transverse dimensions can be controlled to some degree.

[0010] For other types of airbags, such as front and knee airbags, methods such as compression wrapping and thermoforming can be used to control the package size. These methods are not ideal for curtain airbags. Curtain airbag packages are large / long and therefore unsuitable for placement in a thermoforming oven. Furthermore, thermoforming is a relatively expensive option for curtain airbags. Therefore, while thermoforming is a potential option for packaging curtain airbags, it may be impractical due to cost and difficulty. Regarding compression wrapping, it often loosens over time and often fails to provide the required reduction in package size. Moreover, the wrapping lacks the ability to force a specific shape and instead conforms only to whatever shape the airbag has when rolled up / folded upon application of the wrapping. Summary of the Invention

[0011] A device for aiding in the protection of vehicle occupants includes a curtain airbag in a sealed state, wherein the curtain airbag is rolled up and / or folded for mounting along a roof longitudinal beam in the vehicle. The curtain airbag includes a channel feature configured to receive a sealing support structure configured to reinforce a predetermined configuration of the curtain airbag in the sealed state.

[0012] According to one aspect, a device for aiding in the protection of vehicle occupants includes an airbag module comprising a curtain airbag in a sealed state, wherein the curtain airbag is positioned in a rolled-up and / or folded configuration for mounting along a roof longitudinal beam in a vehicle. The curtain airbag can be configured to inflate and deploy along a side structure of the vehicle structure. The device may further include a sealing retention structure mounted within the curtain airbag when in the sealed state. The sealing retention structure can be configured to deform the rolled-up and / or folded configuration of the curtain airbag from within the curtain airbag to reinforce the shape of the airbag module.

[0013] According to another option, the curtain airbag may include a channel for receiving the encapsulation maintenance structure.

[0014] Alternatively, the channel can be positioned along the lower edge of the curtain airbag.

[0015] Alternatively, the channel may have an opening for receiving the encapsulation support structure.

[0016] Alternatively, the opening can be located at the front end of the curtain airbag.

[0017] According to another aspect, the airbag may include an extension of a lower edge portion that projects forward from the front edge portion of the airbag, the extension including an opening that provides a pathway to the access channel.

[0018] On the other hand, the opening can have an outwardly tapering configuration and be angled upwards relative to the length of the channel.

[0019] According to another aspect, the extension may include an aperture configured to receive a tool for securing the extension to form resistance to the extension and retraction of the lower edge portion of the airbag, the extension and retraction of the lower edge portion of the airbag occurring in response to mounting the encapsulation support structure into the channel.

[0020] According to another aspect, the extension may include an orifice configured to receive a tool for securing the extension to form resistance to the extension and retraction of the lower edge portion of the airbag, the extension and retraction of the lower edge portion of the airbag occurring in response to the removal of the folding rod from the airbag module.

[0021] According to another option, the opening in the extension can be kept closed by at least one of stitching, ultrasonic welding, thermal bonding or adhesive to hold the encapsulation support structure in the channel.

[0022] According to another aspect, the opening in the extension may include an overlying portion forming a curved tab, the curved tab being configured to facilitate separation of the overlying portion, so that the encapsulation retaining structure can be installed in the channel.

[0023] According to another aspect, the device also includes a wrapping structure configured to extend around the curtain airbag in a rolled-up and / or folded state to hold the curtain airbag in a sealed state and limit the expansion of the curtain airbag in the sealed state.

[0024] According to another aspect, since the wrapping structure restricts the expansion of the curtain airbag in the sealed state, the sealing maintenance structure is configured to reinforce the shape of the channel and the shape of the portion of the curtain airbag rolled up and / or folded around the sealing maintenance structure and the channel.

[0025] According to another approach, the roll-up and / or folded curtain-like airbag can define an internal space configured to receive an encapsulation support structure. The encapsulation support structure can be configured to have an outer perimeter approximately equal to the perimeter of the internal space, such that when the encapsulation support structure is installed, the roll-up and / or folded airbag conforms to the shape of the encapsulation support structure.

[0026] According to another option, the wrapping structure can be configured to have a length longer than the outer periphery of the rolled-up and / or folded curtain airbag, wherein the rolled-up and / or folded curtain airbag is configured to unwind and / or unfold to inflate into engagement with the wrapping structure.

[0027] On the other hand, curtain airbags can be single-piece woven curtain airbags or curtain airbags that are cut and sewn together.

[0028] According to another perspective, the device can be included as a component of a vehicle safety system. The vehicle safety system may also include an inflator and a controller, the inflator being configured to inflate the curtain airbag, and the controller being configured to actuate the inflator in response to a vehicle collision. Attached Figure Description

[0029] The foregoing and other features of the invention will become apparent to those skilled in the art from the following description taken in conjunction with the accompanying drawings, wherein:

[0030] Figure 1 This is a schematic diagram showing the encapsulation state of the airbag module of a vehicle safety system in the installed state in the vehicle.

[0031] Figure 2This is a plan view illustrating an example configuration of a curtain airbag that can be implemented in the airbag module of a vehicle safety system.

[0032] Figure 3 yes Figure 2 An enlarged view of a portion of the curtain airbag.

[0033] Figures 4A to 4D The illustration shows the procedure for placing the curtain airbag in a sealed state during the assembly of the airbag module.

[0034] Figure 5A It is roughly along Figure 4B The cross-sectional view taken from line 5A-5A in the diagram.

[0035] Figure 5B It is roughly along Figure 4C The cross-sectional view taken from line 5B-5B in the diagram.

[0036] Figure 5C It is roughly in Figure 4C An enlarged view of a portion of the airbag module shown at line 5C.

[0037] Figure 5D It is roughly along Figure 4D The cross-sectional view taken from line 5D-5D in the diagram.

[0038] Figure 5E It is roughly along Figure 4D The cross-sectional view taken from line 5E-5E in the diagram.

[0039] Figure 6 The diagram illustrates a method for placing a curtain airbag in a sealed state.

[0040] Figure 7 This is a schematic diagram illustrating the dimensional characteristics utilized in the design of the airbag module. Detailed Implementation

[0041] refer to Figure 1 and Figure 2 The vehicle safety system 10 includes an airbag module 20 for helping to protect the occupants of the vehicle 12. The airbag module 20 includes an inflatable vehicle occupant protection device in the form of a curtain airbag 14.

[0042] The curtain airbag 14 can be constructed from any suitable material such as nylon (e.g., woven nylon 6-6 yarn) and can be constructed in any suitable manner. For example, the curtain airbag 14 can have a single-piece braided (OPW) construction, in which the airbag is woven as a single piece of material, wherein double-layer portions form the overlay panel 22 and single-layer portions define connections or seams 30, 36. As another example, the curtain airbag 14 may include separate overlay panels 22 interconnected by known methods (such as stitching, ultrasonic welding, thermal bonding, or adhesives) to form the connections / seams 30, 36 of the curtain airbag 14. The curtain airbag 14 can be uncoated, coated with a material such as impermeable polyurethane, or laminated with a material such as an impermeable membrane. Thus, the curtain airbag 14 can have an airtight or substantially airtight construction. Those skilled in the art will appreciate that alternative materials (such as polyester yarn) and alternative coatings (such as silicone) can also be used to construct the curtain airbag 14.

[0043] Figure 1 and Figure 2 The curtain airbag 14 is just one of many example configurations that can be implemented in the vehicle safety system 10. Airbag configurations can vary considerably from vehicle to vehicle, depending on a number of factors, such as the vehicle's architecture and the desired level or extent of airbag coverage. Figure 1 and Figure 2 The curtain airbag 14 includes several typical features of most (if not all) curtain airbags. A peripheral connection 30 defines an inflatable volume 32 of the curtain airbag, which is divided into inflatable chambers 34 by an internal connection 36 within the peripheral connection. An inflator port 40 is configured to receive an inflator 50 (see [link to inflator 50]). Figure 2 This allows the inflation fluid to be guided from the inflator into the inflatable volume 32.

[0044] A series of mounting tabs 42 are spaced apart along the upper edge 68 of the curtain airbag 14 and facilitate the attachment of the airbag and airbag module 20 to the vehicle 12. Each of the mounting tabs 42 may include one or more mounting openings 44. Typically, the airbag module is attached to the vehicle at or near the intersection of the side structure 16 and the vehicle roof 18, above the vehicle doors and side windows (not shown). The airbag module 20 may, for example, be mounted to the roof longitudinal beam of the vehicle 12. When inflated, the curtain airbag 14 is positioned between the side structure 16 and the vehicle occupants and extends along the length of the vehicle 12, serving to mount the encapsulation support structure into the channel 100, as described below.

[0045] exist Figure 2In its installed state, the airbag module 20 includes a curtain airbag 14 in a sealed state and an inflator 50, which is fixed in the inflator port 40 in a known manner, such as via a clamp (not shown). The inflator 50 can be of any known type, such as a gas-storing, solid propellant, enhanced, or hybrid type. The inflator 50 is operatively connected, for example via a lead wire, to an airbag controller 52 configured to actuate the inflator in response to sensing the occurrence of an event for which occupant protection is desired, such as a collision or rollover event.

[0046] Airbag module 20 includes a curtain-type airbag 14 in a collapsed, flattened, rolled-up, and / or folded state. This can be achieved, for example, by extending the lower edge portion of the curtain-type airbag 14 (as shown in...) Figure 1 (As can be seen from the image) This is accomplished by rolling up and / or folding the curtain airbag 14 upwards toward the upper edge of the airbag. This places the curtain airbag 14 in a sealed state, and the airbag module 20 is ready for installation. "Sealed" or "sealed" means that the curtain airbag 14 remains rolled up and / or folded in the storage state, so that the airbag module 20 can be installed as a unit in the vehicle 12.

[0047] In the enclosed state, the rolled-up / folded state of the curtain airbag 14 can be maintained by a wrapping structure, such as tape, straps, wrapping material, tether, or sheath, which can rupture to release the airbag for deployment in response to inflation. Figure 1 An example wrapping structure 60 is shown. The wrapping structure 60 is typically formed separately from the curtain airbag 14 and attached during assembly. However, the wrapping structure 60 can be formed as an integral part of the curtain airbag 14.

[0048] The wrapping structure 60 can have various constructions. For example, the wrapping structure 60 can be an OPW fabric structure that slides on and is positioned along the length of the rolled-up curtain airbag 14. As another example, the wrapping structure 60 can be wrapped around the rolled-up curtain airbag 14 with tape and secured by its adhesive backing. As another example, the wrapping structure 60 can be a woven fabric structure, such as strips cut and sewn to form loops. As another example, the wrapping structure 60 can be a non-woven fabric structure, such as strips cut and secured by adhesive or welding to form loops.

[0049] In the installed state, the airbag module 20 is secured to the structure of the vehicle 12 via a mounting tab 40, for example, by a fastener (not shown) that passes through an opening 42 in the mounting tab. Because the airbag module 20 includes a curtain airbag 14, the structure to which the module is connected is at or near the intersection of the roof 18 and the side structure 16 of the vehicle 12. Examples of structures to which the airbag module 20 can be connected include the side structure 16, the roof 18, or portions thereof, such as roof longitudinal beams or pillars (A, B, C, D, etc.).

[0050] In the installed state, the airbag module 20 is concealed behind trim pieces (such as headliners, roof rail trim pieces, or pillar trim pieces). Typically, the available space between the trim pieces and the vehicle structure is limited, making the dimensions of the encapsulated airbag 14 extremely important. Therefore, the airbag module includes features that help create and maintain the desired encapsulation configuration of the airbag module 20 or at least a portion thereof. "Encapsulation configuration" means that the airbag 14 and / or the airbag module 20 include features that help create and maintain the desired shape and size of the airbag module 20 or a portion thereof.

[0051] The curtain airbag 14 includes features configured to help encapsulate the airbag so that the airbag or a portion thereof maintains a desired encapsulation configuration. More specifically, the curtain airbag 14 includes a channel 100 configured to receive an encapsulation retention structure 120 (see especially...). Figure 1 , Figure 4C and Figure 4D The encapsulation support structure 120 is configured to help generate and maintain the desired encapsulation configuration of the curtain airbag. Figure 2 In the example configuration, channel 100 is formed along the lower edge portion 64 of curtain airbag 14 at the front edge portion 62 of the airbag. The location and extent of channel 100 coincide with a portion of curtain airbag 14 for which maintaining a small package size is important. For example, the location and extent of channel 100 may coincide with a portion of airbag module 20, which is positioned behind the A-pillar trim during installation, where available space may be limited.

[0052] like Figure 2 and Figure 3 As shown, the channel 100 is defined by a connection 102 of the upper covering panel 22 of the curtain airbag 14. The connection 102 is generally rectangular in form, which makes the channel 100 an envelope of the upper covering portion of the panel 22. An opening 104 of the channel 100 provides access to the interior of the channel, thereby allowing insertion of a package-supporting structure. Figures 1 to 3 In the example configuration, the mouth 104 is formed in the extension 106 of the curtain airbag 14, which extends forward from the front edge 70 of the curtain airbag 14.

[0053] like Figure 3 As best shown, the opening 104 is defined by a portion of the connecting portion 102 that extends slightly upward at an angle relative to the length of the curtain airbag 14. As shown, the portion of the connecting portion 102 defining the opening 104 may also taper outwards, slightly diverging. A curved tab 110 formed at the opening 104 allows for the separation of the airbag panel 22 to facilitate access to the channel 100. The extension 106 also includes an opening 112 for facilitating the use of one or more folding rods when sealing the curtain airbag 14.

[0054] The location and extent of channel 100 can vary depending on the desired control of the package size along the length of airbag module 20. For example, it may be desirable to control the package size along the entire length of airbag module 20, such that channel 100 can be configured to extend the length of curtain airbag 14. As another example, it may be desirable to control the package size of airbag module 20 along the rear portion of curtain airbag 14, so channel 100 can be configured to extend along the rear portion of curtain airbag 14, for example, intersecting with the rear edge portion 66 of curtain airbag. As yet another example, it may be desirable to control the package size of airbag module 20 along more than one portion of curtain airbag 14, so multiple channels 100 may exist, each channel 100 including a package retention structure 120, or alternatively, a single channel and a single package retention structure, wherein the channel and / or structure are configured to control the package size only in those portions of the airbag module.

[0055] The manner in which channel 100 and encapsulation support structure 120 control the encapsulation size of curtain airbag 20 is best understood when interpreted in conjunction with the method or procedure for placing curtain airbag 14 in the encapsulated state. This method / procedure... Figure 6 As shown in the figure, and can be combined Figures 4A to 4D and Figures 5A to 5E To describe.

[0056] refer to Figure 6 The procedure or method 200 for placing the curtain airbag 14 in a sealed state includes step 202 of applying a folding bar 150. For this purpose, refer to... Figure 4A The curtain airbag is placed flat on the assembly table, for example, and a folding / rolling-up aid, such as a folding rod 150, is positioned on top of the curtain airbag 14, for example, at or along the lower edge portion 64 of the curtain airbag. In step 204, the curtain airbag 14 is rolled up / folded around the folding rod 150, as... Figure 4A The curved arrow, generally marked A, indicates this. In doing so, the folding bar 150 allows the curtain airbag 14 to be rolled up tightly around the bar in a consistent and uniform manner. The dimensions of the folding bar 150 can be selected to give the rolled-up / folded curtain airbag 14 the desired size configuration; the folding bar 150 may, for example, have a rectangular cross-section.

[0057] When the roll-up / folding is complete, the curtain airbag 14 remains in place. Figure 4B The diagram illustrates a state where the folding rod 150 is positioned at the center of the rolled-up / folded airbag. Due to the tight roll-up / folding of the curtain airbag 14, the folding rod 150 is held firmly in this position. As shown at step 206, it is at this stage that the wrapping structure 60 is applied. Figure 5AThe diagram shows the state of the curtain airbag 14 and the wrapping structure 60 when step 206 is completed. It should be noted that the wrapping structure does not fit tightly around the rolled-up curtain airbag 14, and therefore, a gap 152 is formed between the outer surface 154 of the rolled-up curtain airbag and the wrapping structure 60.

[0058] In step 208, the folding rod 150 retracts, that is, rotates in the unwinding direction, as generally from Figure 5B As indicated by the arrow marked B. As a result of this retraction, the tightness of the rolled-up curtain-like airbag 14 loosens, causing the outer surface 154 to expand and engage with the wrapping structure 60, as... Figure 5B As shown in the figure. In the example configuration illustrated in the figure, the folding lever 150 retracts a quarter turn, or 90 degrees. However, depending on the desired configuration of the encapsulated curtain airbag 14, the folding lever 150 may retract up to two full turns or more.

[0059] When the folding rod 150 retracts, due to the loosening of the rolled-up curtain airbag 14 and the accompanying expansion of the outer surface 154, space 156 (see Figure 5B The folding bar 150 is opened around the folding bar. In step 210, the folding bar 150 is removed from the rolled-up curtain airbag 14, where the loosened airbag roll and the resulting space 156 facilitate easy and smooth removal. When the folding bar is removed, the rolled-up curtain airbag 14 may have a tendency to “stretch”, that is, one or more internal coils of the rolled-up / folded curtain airbag may be pulled out due to friction with the folding bar. This stretching can disrupt the rolling / folding of the curtain airbag 14.

[0060] To counteract stretching, the opening 112 of the extension 106 is positioned axially beyond the end of the rolled-up / folded curtain airbag, as it extends forward from the front edge of the curtain airbag 14. Therefore, a tool 114 (such as a hook) can be hooked through the opening 112 and used to secure the extension 106. This is in Figure 5C The details are shown below. For example, tool 114 can be a fixing device mounted on an assembly table. The lower edge portion 64 of the curtain airbag 14 is located at the innermost part of the roll / fold, i.e., it abuts against the folding rod 150, and the portion of the curtain airbag directly engaging the folding rod is secured by hook 114. Therefore, when the folding rod 150 is removed from the end of the curtain airbag 14 opposite the extension 106, as Figure 4C The arrow marked B in the middle roughly indicates that the hook 114 is fixed to the curtain airbag to prevent it from rolling out / folding during telescopic movement.

[0061] The wrapping structure 60 and / or the folding bar 150 can be configured to facilitate the use of the encapsulation retention structure 120. When the curtain airbag 14 is rolled up around the folding bar 150 and the wrapping structure 60 is applied, the resulting structure... Figure 5AAs shown, when rolled up around a generally rectangular (cross-section), the curtain airbag 14 takes on a generally rounded rectangular shape. This shape is due to the wrapping structure 60 maintaining the curtain airbag 14 wrapped around the rectangular folding rod 150. However, once the folding rod 150 is removed, the curtain airbag 14 and the wrapping structure 60 return to a circular configuration as the curtain airbag and the wrapping structure tend to move to a state of minimum stress. This is in Figure 5D As shown in the image.

[0062] Referring to step 210, once the folding rod 150 is removed, install the encapsulation and retention structure 120, as follows: Figure 4C As indicated by the arrow generally marked D, the encapsulation holding structure 120 can be configured to form a tight fit within the channel 100. Therefore, there is a risk that the rolled-up / folded curtain airbag 14 may stretch or otherwise become displaced in the direction in which the encapsulation holding structure 120 is inserted. Advantageously, the hook 114 can secure the extension 106 by anchoring the lower edge portion 64 of the curtain airbag 14 to prevent such displacement.

[0063] The encapsulation support structure 120 and the channel 100 are configured such that when the encapsulation support structure is installed, the rolled-up curtain airbag 14 (see Figure 5E The space 158 at the center of the airbag 14 is completely or substantially filled by its structure. Therefore, the rolled-up curtain airbag 14 takes the shape of the encapsulation support structure 120, which, in the example configuration, is rectangular. Because the rolled-up curtain airbag 14 is constrained by the wrapping structure 60, both the airbag and the wrapping structure follow or conform to the cross-sectional shape of the encapsulation support structure 120. Therefore, the encapsulation support structure 120 strengthens... Figure 5E The rolled-up curtain airbag 14 shown is generally rectangular in configuration, which facilitates installation within the necessary space in the vehicle.

[0064] When installed in the curtain airbag 14, the encapsulation and support structure 120 becomes part of the airbag module 20 installed in the vehicle 12. Therefore, the encapsulation and support structure 120 remains installed in the channel 100 so that the shape of the encapsulated curtain airbag 14 / airbag module 20 is maintained even after the module is installed in the vehicle 12. Maintaining the shape of the curtain airbag 14 / airbag module 20 is important so that trim pieces can be installed, covering and concealing the airbag module 20.

[0065] The encapsulation and maintenance structure 120 can be constructed from a variety of materials. Since its purpose is to be permanently installed within the curtain airbag 14 to maintain the shape of the encapsulated airbag / airbag module 20, the encapsulation and maintenance structure 120 is configured to be both robust and lightweight, enabling it to perform its shape-maintaining purpose without contributing a significant amount of energy to the deployed airbag. The encapsulation and maintenance structure can be formed, for example, from plastic / polymer materials such as nylon, polyester, PET, PVC, HOPE, etc.

[0066] The curtain-type airbag 14, specifically the portion forming the channel 100 and the extension 106, includes features that, once installed, help maintain the position of the encapsulation support structure 120 within the channel 100. First, the opening 104 is angled relative to the length of the channel 100 and configured such that installation of the encapsulation support structure 120 requires displacement of the extension 106 to insert into the encapsulation support structure. The tapered expansion configuration of the connector 102 at the opening 104 facilitates the installation of the encapsulation support structure 120, but the angled configuration of the opening must still be overcome. Once the encapsulation support structure 120 is installed, the angled opening helps prevent its accidental removal from the channel 100. For a more secure fit, stitching, ultrasonic welding, thermal bonding, or adhesive can be applied across the opening 104 to the extension 106 to seal the encapsulation support structure 120 internally, as generally indicated at line 116.

[0067] The dimensions of the encapsulation support structure 120 and the channel 100 are calculated based on one or more desired dimensions of the curtain airbag 14 in the encapsulated state. Figure 7 An example of this is shown in the image. (Reference) Figure 7 The curtain airbag 14 is rolled up with a roll tightness comparable to that of the example curtain airbag installation. In this rolled-up configuration, the rolled-up curtain airbag 14 has an internal dimension or diameter ID and an external dimension or diameter OD. In this specification, the term "diameter" is used to describe the size of the curtain airbag 14 because the rolled-up / folded airbag is considered to be in an ideal circular rolled-up configuration, which facilitates circumference / perimeter calculations and other determinations described herein. Those skilled in the art will appreciate that this scheme is not affected by the fact that the curtain airbag 14 is capable of and likely to deform when placed in a sealed state. The "circumference" dimension of a deformed non-circular roll is simply better described as the "perimeter" dimension of the roll, which remains equal to the calculated circumference of a circular roll. This is because the wrapping structure 60 fixes the roll and restricts its expansion despite any deformation of the roll's shape. Therefore, although considering Figure 7 In the case of this circular configuration, the ID / OD values ​​are determined / described, but the validity / accuracy of these values ​​is maintained even when considering the possibility / probability of non-circular configurations in practice. The following table illustrates the calculations performed in determining the dimensions of the package support structure 120, with dimensions in millimeters (mm):

[0068] Figure 7 The illustration shows the rolled-up curtain airbag 14 with reference to the X, Y, and Z axes. The labeling of these axes is not particularly important, although for convenience they can correspond to the typical XYZ axis labeling of a vehicle, i.e., the X-axis corresponds to vehicle length, the Y-axis to vehicle width, and the Z-axis to vehicle height. For a specific vehicle configuration, the expected thickness of the encapsulated curtain airbag might be 14 mm along the Y-axis. Refer to the table above and... Figure 7 The example configuration shown in the figure has an OD of 30 mm and an ID of 18 mm in the rolled-up state. This results in a rolled-up fabric thickness of 6 mm, approximately... Figure 7 The letter T is used to indicate this. Therefore, in order to achieve the desired 14 mm package thickness in the Y direction, the package support structure has a thickness of 2 mm, such that the 6 mm roll-up fabric thickness T on each side of the package support structure plus the 2 mm thickness of the structure itself results in a total of 14 mm.

[0069] Since the ID of the rolled-up curtain airbag is fixed at 18 mm, the circumference of the ID (C) is known. ID The diameter is approximately 56 mm, and this circumference should be approximately equal to the circumference (P) of the package support structure 120. If the ID circumference C... ID Configured to correspond to or approximately equal to the perimeter of the encapsulation support structure 120, the encapsulation support structure, when inserted into the insertion channel 100, will force the ID of the curtain airbag 14 to conform to the cross-sectional shape of the encapsulation support structure. Through simple mathematical calculation, an encapsulation support structure with a width (W) of 2 mm and a height (H) of 26 mm has a perimeter of 56 mm. Therefore, the 2 × 26 mm encapsulation support structure will precisely fit within the ID of the rolled-up curtain airbag 14 and conform to its shape, resulting in a desired encapsulation thickness of 14 mm.

[0070] To ensure that the desired size of the airbag module 20 is achieved by the mounting of the encapsulation support structure 120, the size of the channel 100 can also be configured to correspond to or be approximately equal to the ID circumference C of the rolled-up curtain airbag 14. ID This provides a channel 100 for receiving the encapsulation support structure 120, ensuring that its installation within the rolled-up curtain airbag 14 does not interfere with the rolled-up structure, for example, by preventing telescoping. Equally important, dimensionalizing the channel 100 in this manner helps ensure the assembly of the airbag module 20 (e.g., according to…) Figure 6Method 200) proceeds as planned. Since the channel 100 is configured to fit snugly / closely with the package retaining structure 120, and since the fit between the package retaining structure and the ID of the rolled-up curtain airbag 14 is configured to fit snugly / closely, any loosening or gaps in the rolled-up curtain airbag around the package retaining structure when installed in the channel will indicate an error.

[0071] Of course, the perimeter of the encapsulation maintenance structure 120 cannot be configured to be exactly equal to the ID circle circumference C. ID Certain tolerances are required for the fit between the channel 100 and the ID of the rolled-up curtain airbag 14 to allow for the installation and assembly of the airbag module 20. Tolerances can be added and configured such that the airbag module 20 can be assembled while still producing the desired cross-sectional shape.

[0072] In the example configuration illustrated in the accompanying drawings, the encapsulation support structure 120 is formed as an elongated member, such as a rod, having a generally rectangular cross-section. The edges / corners of the encapsulation support structure 120 may be chamfered or rounded to reduce sharp edges that could cut or damage the airbag material, especially in a tight-fitting configuration. Additionally, to facilitate insertion of the encapsulation support structure 120 into the channel in these tight-fitting configurations, the encapsulation support structure may include a tapered or rounded end portion 122 that guides the structure into the channel.

[0073] Figures 5D to 5E The cross-sectional view illustrates how the encapsulation support structure 120 works together with the channel 100 to shape the encapsulated curtain airbag 14 / airbag module 20. Figure 5D A curtain airbag 14 in a rolled-up / folded state is shown, wherein the wrapping structure 60 is fixed to the airbag in a tightly molded manner by a folding rod 150, which has been removed. Without any structure defining the shape of the encapsulated curtain airbag 14 / airbag module 20, it is free to take on any shape determined by the nature of the rolled-up / folding structure and / or any applied external force. As an example, the cross-sectional shape of the encapsulated curtain airbag 14 / airbag module 20 is generally circular.

[0074] In the rolled-up / folded state, the lower edge portion 64 of the curtain airbag 14, and therefore the channel 100, is positioned at the innermost part of the rolled-up / folded state. The cross-sectional dimensions of the channel 100 are configured such that the encapsulation retaining structure 120 fits snugly inside the channel. As a result, as Figure 5E As shown, the installation of the encapsulation support structure 120 deforms the rolled-up / folded state of the curtain airbag 14 / airbag module 20, forcing the channel 100 and the surrounding curtain airbag / airbag module to conform to the shape of the encapsulation support structure.

[0075] Because the encapsulation structure 60 restricts and maintains the overall diameter of the encapsulated curtain airbag 14 / airbag module 20, the rolled-up / folded curtain airbag follows when the channel 100 conforms to the cross-sectional shape of the encapsulation maintenance structure 120. Figure 5E In the example configuration illustrated, the encapsulation support structure 120 has a generally rectangular cross-section, and the channel 100, the curtain airbag 14, and the airbag module 20 conform to this shape. As a result, the encapsulated curtain airbag 14 and airbag module 20 are shaped by the channel 100 and the encapsulation support structure 120, and this shape is maintained throughout the installation and after the airbag module is installed.

[0076] Therefore, it can be understood that the shape of the encapsulated curtain airbag 14 and airbag module 20 can be controlled by the configuration of the channel 100 and the encapsulation holding structure 120. Not only can the shape be controlled as shown in the cross-sectional dimensions in the example configuration, but also the directional range of the encapsulated curtain airbag 14 and airbag module 20 can be controlled. For example, by forming the encapsulation holding structure 120 with a curved configuration, the encapsulated curtain airbag 14 and airbag module 20 can be made to follow a curved path. Forming the channel 100 with a corresponding curved configuration helps maintain the shape of the encapsulated curtain airbag 14 / airbag module 20. As another example, the encapsulated curtain airbag 14 and airbag module 20 can be made into a twisted or angled form by forming the encapsulation holding structure 120 with twisted or angled sections.

[0077] Based on the above description of the invention, those skilled in the art will recognize improvements, variations, and modifications to the invention. Such improvements, variations, and modifications within the scope of the art are intended to be covered by the appended claims.

Claims

1. A device for helping to protect vehicle occupants, comprising: An airbag module comprising a curtain airbag in a sealed state, wherein the curtain airbag is positioned in a rolled-up and / or folded configuration for mounting along a roof longitudinal beam in a vehicle, and the curtain airbag is configured to inflate and deploy along a side structure of the vehicle structure. An encapsulation and maintenance structure is installed in the curtain airbag when the curtain airbag is in the encapsulated state. The encapsulation and maintenance structure is configured to deform the rolled-up and / or folded configuration of the curtain airbag from within the curtain airbag to reinforce the shape of the airbag module.

2. The device according to claim 1, wherein, The curtain-type airbag includes a channel for receiving the encapsulation maintenance structure.

3. The device according to claim 2, wherein, The channel is positioned along the lower edge of the curtain-type airbag.

4. The device according to claim 3, wherein, The channel has an opening for receiving the encapsulation sustaining structure.

5. The device according to claim 4, wherein, The opening is located at the front end of the curtain airbag.

6. The device according to claim 3, wherein, The airbag includes an extension of a lower edge portion that projects forward from the front edge portion of the airbag, the extension including an opening that provides access to the channel.

7. The device according to claim 6, wherein, The opening has an outwardly tapering configuration and is angled upwards relative to the length of the channel.

8. The device according to claim 6, wherein, The extension includes an aperture configured to receive a tool for securing the extension to create resistance to the extension of the lower edge portion of the airbag, the extension of the lower edge portion of the airbag occurring in response to mounting the encapsulation support structure into the channel.

9. The device according to claim 6, wherein, The extension includes an orifice configured to receive a tool for securing the extension to create resistance to the extension and retraction of the lower edge portion of the airbag, the extension and retraction of the lower edge portion of the airbag occurring in response to the removal of a folding rod from the airbag module.

10. The device according to claim 6, wherein, The opening in the extension is kept closed by at least one of stitching, ultrasonic welding, thermal bonding, or adhesive to hold the encapsulation support structure in the channel.

11. The device according to claim 6, wherein, The opening in the extension includes an overlying portion forming a curved tab, the curved tab being configured to facilitate separation of the overlying portion so that the encapsulation holding structure can be installed in the channel.

12. The device of claim 1, further comprising a wrapping structure configured to extend around the curtain airbag in the rolled-up and / or folded state to hold the curtain airbag in the enclosed state and limit the expansion of the curtain airbag in the enclosed state.

13. The device according to claim 12, wherein, Since the encapsulation structure restricts the expansion of the curtain airbag in the encapsulated state, the encapsulation maintenance structure is configured to reinforce the shape of the channel and the shape of the portion of the curtain airbag rolled up and / or folded around the encapsulation maintenance structure and the channel.

14. The device according to claim 12, wherein, The roll-up and / or folded curtain-like airbag defines an internal space configured to receive the encapsulation and support structure, wherein the encapsulation and support structure is configured to have an outer perimeter approximately equal to the perimeter of the internal space, such that when the encapsulation and support structure is installed, the roll-up and / or folded airbag conforms to the shape of the encapsulation and support structure.

15. The device according to claim 12, wherein, The wrapping structure is configured to have a length longer than the outer periphery of the rolled-up and / or folded curtain airbag, wherein the rolled-up and / or folded curtain airbag is configured to unwind and / or unfold to inflate into engagement with the wrapping structure.

16. The device according to claim 1, wherein, The curtain-type airbag is either an integrally woven curtain-type airbag or a curtain-type airbag that is cut and sewn together.

17. A vehicle safety system, comprising: The device according to claim 1; An inflator configured to inflate the curtain-type airbag; and A controller configured to actuate the inflator in response to a vehicle collision.

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