Occupant restraint airbag cushion

Abstract

Occupant restraint airbag cushion (16) for mounting on a seat (10) in a motor vehicle, which inflates inwards from the occupant to provide side impact restraint of the occupant, comprising: a plate (26) facing the occupant and a plate (28) opposite the plate (26) facing the occupant, a mounting section mounted on a seat back of the seat (10), an upper half section of the pillow (22) for positioning near the occupant's head, a lower cushion half section (20) for positioning next to the occupant's upper body with a central, unfilled area (110) which is surrounded by a tubular, inflated ring with two filled areas (126, 140) extending from the central, unfilled area (110) towards the occupant, wherein the upper half of the cushion section (22) has a tubular, inflated cushion area (120) which is positioned laterally to the occupant's head, characterized by the fact that the tubular, inflated cushion area (120) has a larger diameter when viewed in vertical section than either of the two filled areas (126, 140) of the tubular, inflated ring and extends further towards the occupant than the tubular, inflated ring surrounding the central, unfilled area (110) to provide an enlarged cushioning surface (118) to support the side of the occupant's head in the event of a side impact.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to an occupant restraint airbag in a motor vehicle and, more particularly, to an airbag cushion mounted inboard of the vehicle seat for providing side impact restraint of the occupant. BACKGROUND OF THE INVENTION

[0002] It is known to equip motor vehicles with an inflatable airbag comprising a cushion for restraining an occupant. It has been proposed to mount an airbag on the inside of a vehicle seat to restrain the occupant against sideways movement within the vehicle and to provide cushioning between the occupant and other interior objects.

[0003] It would be desirable to provide an improved airbag cushion which would provide improved restraint of the occupant against lateral movement within the vehicle and improved cushioning capability.

[0004] Conventional occupant restraint airbags are known from the documents DE 10 2011 084 093 A1, US 2012 / 0 091 697 A1, WO 97 / 06987 A1, DE 10 2005 059 197 A1, US 7 549 672 B2, DE 196 22 225 A1, US 5 636 862 A and GB 2 322 338 A. SUMMARY OF THE INVENTION

[0005] The present invention is defined by the features of the accompanying independent main claim. Advantageous further developments can be found in the following description and the dependent claims.

[0006] A side-impact airbag cushion for mounting on a seat in a motor vehicle includes an occupant-facing panel and a panel opposite the occupant-facing panel, and a mounting portion mounted on the seatback. An upper cushion half portion is positioned near the occupant's head, and a lower cushion half portion is positioned adjacent the occupant's torso. The cushion half portion includes a central uninflated region surrounded by a tubular inflated ring extending from the central uninflated region toward the occupant.The upper cushion half portion includes a tubular inflated cushioning region positioned laterally of the occupant's head and extending farther toward the occupant than the tubular inflated ring surrounding the central unfilled region, thereby providing an enlarged cushioning surface for supporting the side of the occupant's head during a side impact.

[0007] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the invention, are intended for purposes of illustration only. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will be more fully understood from the detailed description and the accompanying drawings in which: Fig. 1 is a perspective view of an airbag cushion inflated between a driver and a console. Fig. 2 another perspective view of the airbag cushion of Fig. 1 is. Fig. Figure 3 is an exploded view showing the sheets of flexible material being fitted together to create the cushion. Fig. 4 the plates of flexible material attached to each other Fig. 3 and shows a gas generator, a diffuser and a mounting bracket ready for assembly. Fig. Figure 5 is a side view of the assembled cushion facing the occupant. Fig. 6 a side view along the direction of arrows 6 - 6 of Fig. 5 is. Fig. 7 a side view along the direction of arrows 7 - 7 of Fig. 5 is. Fig. 8 a side view along the direction of arrows 8 - 8 of Fig. 5 is. Fig. 9 a side view along the direction of arrows 9 - 9 of Fig. 5 is. Fig. 10 a side view along the direction of arrows 10 - 10 of Fig. 5 is. Fig. 11 a side view along the direction of arrows 11 - 11 of Fig. 5 is. Fig. 12 is a fragment of the lower portion of the cushion showing the flow path of the inflation gas. Fig. Figure 13 is another fragment of the lower portion of the cushion showing an alternative flow path for the inflation gas. Fig. Figure 14 is yet another fragment of the lower portion of the cushion showing an alternative flow path for the inflation gas. Fig. 15 is a fragment of the upper portion of the cushion showing alternatives for the shape of the first and second unfilled areas. Fig. 16 a sectional view along the direction of arrows 16 - 16 of Fig. 12 is. Fig. 17 a sectional view along the direction of arrows 17 - 17 of Fig. 13 is. Fig. 18 a sectional view along the direction of arrows 18 - 18 of Fig. 14 is. DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0009] Referring to Fig. 1, a vehicle occupant, in particular the driver, sits in a vehicle seat 10. The seat may have an armrest, which is not shown. A storage console 12 is mounted on the vehicle body inside the vehicle seat 10 and the occupant. An airbag system 14 is mounted on the inner side of the vehicle seat 10 and includes a cushion 16, which is Fig. 1 and Fig. 2 in its inflated state. As shown in Fig. 1, the cushion 16 includes a lower cushion half portion 20 generally adjacent the occupant's torso and an upper cushion half portion 22 adjacent the occupant's head. Components of the cushion and the gas generator

[0010] Fig. Figure 3 shows the various panels made of a flexible, but generally non-stretchable material from which the cushion 16 is assembled. The panel 26 facing the occupant is Fig. 1. An oppositely facing plate 28 is used by the occupant of Fig. 1. The flexible material of the occupant-facing panel 26 and the opposite-facing panel 28 is tightly woven and coated to prevent the leakage of inflation gas through the material. A circumferential bead of sealant 32, such as a silicone sealant, is applied along the peripheral edge of the opposite-facing panel 28 except for an end portion or inlet 34 which becomes the inlet for an airbag inflator. The sealant 32 will prevent the leakage of inflation gas through the seams between the occupant-facing panel 26 and the opposite-facing panel 28. A relatively large diameter ring 38 of sealant is provided on the opposite-facing panel 28 generally adjacent the occupant's torso and shoulder. Slots 42 and 44 are cut into the opposite-facing panel 28.Sealant encircles 48 and 50 are provided above the encirclement 38 and below an upper edge portion 54 of the oppositely facing plate 28, as shown in FIG. Fig. 3. Furthermore, an optional row or line 58 of sealant is provided connecting the encircles 48 and 50.

[0011] The occupant-facing panel 26 is shaped to overlie the oppositely facing panel 28 and has slots 64 and 66 which overlie the slots 42 and 44. The occupant-facing panel 26 will be disposed on top of the oppositely facing panel 28, as shown in Fig. 4, and bonded thereto using the various beads and circles of sealant. A conventional series of stitches is provided around all peripheral edges between the occupant-facing panel 26 and the opposite-facing panel 28. Furthermore, circles 38, 48, and 50 and row 58 are followed by a series of seams to provide additional fastening between the occupant-facing panel 26 and the opposite-facing panel 28.

[0012] Additional plates made of flexible material, in Fig. 3, include a lower tether 70, a pair of cushion mounting flaps 72 and 74, and an upper tether 78. Assembling the components

[0013] Fig. 4 shows the different sheets of cushion material from Fig. 3 are fully attached to each other to provide the finished cushion 16. In addition, Fig. 4 a mounting bracket 84 with mounting bolts 83 and 85, which are screwed to the seat back. Fig. 4 also shows a gas generator 86 and mounting straps 90 and 92 which will interconnect the mounting bracket 84, the gas generator 86 and the cushion end portion 34. Fig. Figure 5 shows the mounting bracket 84 and the gas generator 86 assembled with the cushion 16. The cushion mounting flaps 72 and 74 are sewn together at stitching line 96 and are sewn to the occupant-facing panel 26 in the opposite-facing panel 28 at a location along an outer peripheral stitching line 98 and at a location along an inner peripheral stitching line 102. The stitching lines 96 and 102 attaching the cushion mounting flaps 72, 74 are sewn through the deflated portions of the cushion. The mounting bolts 83 and 85 project outward and are ready to be installed through bolt apertures in the vehicle seatback.

[0014] As in the Fig. 5 and Fig. 7, the lower tether 70 is located on the occupant-facing panel 26 of the cushion 16, and its rearward end is sewn into the stitch line 96 and also anchored to the mounting bolt 83. The forward end of the lower tether 70 is sewn to the lower cushion half portion 20 at the forwardmost peripheral edge region 100 of the lower cushion half portion 20. In addition, a central portion of the tether 70 extends through the slots 64 and 66 and the slots 42, 44. The lower tether 70 is configured to a length shorter than the distance between its end attachments to the cushion 16 so that when the cushion 16 is inflated, the lower tether 70 flexes the cushion 16 toward the occupant.

[0015] As in the Fig. 5, Fig. 8 and Fig. 9, one end of the upper support cord 78 is sewn into the stitch line 96 and anchored to the mounting bolt 83, and the other end is sewn to the upper cushion half section 22 at an upper peripheral edge area 106 of the cushion 16. As shown in Fig. 5, this stitching of the upper tether 78 preferably takes place around both the uppermost edge and the upper front corner of the upper cushion half section 22 so that the upper tether 78 extends diagonally rearward from the upper airbag section to the mounting stud 83. The upper tether 78 is configured to a length shorter than the distance between its end attachments to the cushion 16 so that when the cushion 16 is inflated, the upper tether 78 flexes the cushion toward the occupant. Inflating the cushion and restraining the occupant

[0016] The Fig. 1, 2, and 5-11 show the inflated cushion 16 in its normal occupant restraint condition, inflated and deployed by activation of the gas generator 86. The use of a leak-resistant, flexible material for the cushion panels 26 and 28 and the use of a sealant to seal the circumferential seams and to seal the perimeters 38, 48, 50, and the series 58 of attachments of the airbag cushion 16 results in a cushion 16 that exhibits very slow leakage to the atmosphere, so that the cushion 16 is capable of remaining inflated for extended periods of time. The lower tether 70 and the upper tether 78 cooperate to hold the inflated airbag cushion 16 in position relative to the seatback so that the inflated cushion 16 will resist inward movement of the occupant.

[0017] The lower sealant encirclement 38, together with the series of stitches around the encircles 38, creates a relatively large uninflated area 110 of the cushion 16, which the sealant prevents inflation gas from reaching. The uninflated area 110 is generally aligned with and receives the occupant's upper torso and shoulder. This uninflated area 110 is shown in the sectional views of the Fig. 7, Fig. 8 and Fig. 9 shown.

[0018] The two smaller upper silicone circles 48 and 50 define unfilled areas 114 and 116 that the inflation gas cannot reach. Furthermore, the optional row 58 of sealant and the associated optional stitches extending between circles 48 and 50 create a connecting line between the unfilled areas 114 and 116.

[0019] With reference to the Fig. 8, Fig. 9 and Fig. 10, an enlarged cushioning surface 118 is provided by an enlarged, bulbous, filled region 120 located above and defined by the upper, unfilled regions 114 and 116 and the optional connecting line 58. In Fig. 9, it can be seen that this cushioning surface 118 and the enlarged, bulbous, filled area 120 constitute the upper cushion half section 22, while the remainder of the cushion 16 below the cushioning surface 118 and the unfilled areas 114 and 116 that form it constitute the lower cushion half section 20, which is in the form of a tubular, inflated ring surrounding the unfilled area 110. As in Fig. As seen in Figure 9, the lower cushion half section 20, when viewed in vertical section, includes the unfilled area 110 positioned at the vertical plane labeled "A" and filled areas 124 and 126 extending generally to the vertical plane labeled "B." The large cushion surface 118 of the upper cushion half section extends in the direction of the occupant's head toward the vertical plane labeled "C."

[0020] As in the Fig. 9 and Fig. As seen in Figure 11, the portion of the filled area 126 located below and between the unfilled areas 114, 116 and the unfilled area 110 of the lower cushion half section 20 provides a secondary cushion surface 121 that will also support the tether 78 when contacted thereby. Viewed in vertical section, the second bulbous filled area 121 extends toward the plane labeled "B." This secondary cushion surface 121 extends farther toward the plane labeled "D" than the adjacent portions of the filled areas 124, 126, and 128.

[0021] During inflation of the cushion 16, a lateral movement of the occupant toward the cushion will result in the upper torso being received in the uninflated area 110, and the occupant's head will be supported by contact with the tether 78, while the tether 78 is in turn supported by the bulbous shape of the cushion surface 118 underlying the upper end of the tether 78. The length of the upper tether 78, assisted by any occupant restraint load exerted on the upper tether 78, will rotate the upper half portion 22 of the inflated cushion 16 toward the occupant's head. Simultaneously, the lower tether 70 will be tensioned and will tend to rotate the lower cushion half portion 20 of the inflated cushion 16 toward the occupant. If necessary, the secondary cushion surface 121 may also provide support for the tether 78. As shown in Fig. 1, the lower cushion half section 20 can be located under the console 12 so that the console 12 also supports the inflated cushion 16. Tuning the pillow's behavior

[0022] It will be appreciated that the provision of the lower unfilled region 110, the pair of upper unfilled regions 114 and 116, and the connecting line 58 provide a uniquely shaped cushion 16 that can be tuned to provide optimal support for a seated occupant. The diameter and shape of the smaller unfilled regions 114 and 116 can be varied to define the size and shape of the filled region 120 and, accordingly, the shape of the cushion surface 118. Fig. For example, Figure 15 shows various alternative paths for the connecting line between the small unfilled areas 114 and 116. Connecting line 58 is straight and extends between the unfilled areas 114 and 116 at approximately the upper ends of the unfilled areas 114 and 116. Connecting line 58a extends between the unfilled areas 114 and 116, but is curved upward. Connecting line 58b is straight and provided at the centerline of the unfilled areas 114 and 116. Connecting line 58e is curved downward.

[0023] Thus, there are many alternative positions for the row 58 of fasteners located between the encircles 48 and 50 defining the unfilled regions 114 and 116 to further tailor the shape and dimensions of the enlarged cushion surface 118 provided by the filled region 120. Fig. 15 also shows that the small unfilled areas 114 and 116 are not restricted to a circular shape. Fig. In Figure 15, the encirclement providing the unfilled area 114 is shown, for example, as having a pill-like or oblong shape. Accordingly, the size and shape of the cushion surface 118 and the second bulbous filled portion 121 can be manufactured with a relatively bulbous and spherical or elliptical shape by adjusting the size, shape, and position of the unfilled areas 114 and 116 and the series of fasteners 58.

[0024] In the sectional view of Fig. 6 shows that the unfilled area 114 is located between a middle filled area 126 and a front filled area 128. Furthermore, the unfilled area 116 is located between the middle filled area 126 and a rear filled area 124. In Fig. 6, the diameter of the front filled area 128 is larger than the diameter of the rear filled area 124. By varying the size of the encircles 48 and 50, which define the unfilled areas 114 and 116, one can control and adjust the sizes of each of these filled areas 124, 126 and 128. Likewise, as in Fig. 7, by controlling the size of the encirclement 38 defining the unfilled area 110, the size and position of the filled areas 132 and 134 located behind and in front of the unfilled area 110 can be precisely determined. As shown in the Fig. 8, Fig. 9 and Fig. 11, the size and position of the encircles 48 and 50 and the size of the unfilled area 110 will also determine the relative size of the filled area 126 and 140, which is located above and below the unfilled area 110, respectively.

[0025] Referring again to the Fig. 2, Fig. 5, Fig. 8 and Fig. 9, it will be seen that the upper tether 78 extends away from the uppermost circumferential edge 106 of the inflated cushion 16, downwardly and diagonally rearwardly over the unfilled regions 114 and 116 and the optional row 58, such that the upper tether completely or partially covers at least one of these upper perimeters 114, 115 and the row 58. Moreover, the upper tether 78 is stretched and extended precisely over the occupant's shoulder, such that contact between the cushion 16 and the occupant's head occurs via contact with this tether 78 and not contact with the unfilled regions 114 and 116, to help define the shape of the cushion provided by the filled region 120.Thus, the upper tether 78 will serve as a membrane outside the inflated cushion 16 and will limit lateral movement of the occupant's head into the uninflated areas 114, 116 and the optional row 58 of the cushion. Controlling pillow inflation

[0026] The Fig. 12, Fig. 13 and Fig. 14 show in their respective sectional views, which are shown in the Fig. 16, Fig. 17 and Fig. 18, alternative arrangements for controlling the inflation of the cushion 16. In Fig. 12, a line of sewn seam or sealant 150 is provided between the occupant-facing panel 26 and the oppositely facing panel 28 so that the inflator gas flow will continue upward around the rear of the cushion 16 and around the uninflated area 110, inflating the upper cushion half portion 22 of the cushion 16 before the inflation gas continues back down around the front of the uninflated area 110 to inflate the forwardmost portion of the lower cushion half portion 20 of the cushion 16. In the Fig. 13 and Fig. 17, no such wall is present to separate the inflation gas entering at the inlet 34, so that the inflation gas can immediately progress around both sides of the unfilled portion 110 to accomplish the simultaneous inflation of the entire cushion 16. In the Fig. 14 and Fig. 18, a line of seam or sealant 154 is provided extending slightly forward from and part way around the unfilled area 110 to permit partial filling of the lowermost portion of the cushion 16 below the filled unfilled area 110, while restricting the filling of the forwardmost portion of the cushion 16 with gas from a gas path above the unfilled area 110. By selecting among the options of Fig. 12, Fig. 13 and Fig. 14, we have found that the inflation of the cushion can be tuned to provide optimal support and interaction with the vehicle armrest adjacent the lower cushion portion 20 and with the occupant's inboard arm.

[0027] Some additional alternatives are also possible. The cushion described herein is constructed from separate panels attached by silicone beads and stitching. As an alternative, portions of the cushion 16, or the cushion as a whole, could be constructed by weaving. The cushion 16 is also configured such that the lower cushion half portion 20 deploys adjacent to the center console 12. The cushion 16 may also be shaped such that the lower portion 20 deploys above the center console 12. Finally, the sealant 32, 38, 48, 50, 58 may be applied to the occupant-facing panel 26 during cushion construction, rather than the opposite-facing panel 28.

Claims

[1] An occupant restraint airbag cushion (16) for mounting on a seat (10) in a motor vehicle which inflates internally from the occupant to provide side impact restraint of the occupant, comprising: a plate (26) facing the occupant and a plate (28) opposite the plate (26) facing the occupant, a mounting section mounted on a seat back of the seat (10), an upper cushion half section (22) for positioning near the occupant's head, a lower cushion half section (20) for positioning next to the occupant's upper body, having a central, unfilled region (110) surrounded by a tubular, inflated ring with two filled regions (126, 140) extending from the central, unfilled region (110) toward the occupant, wherein the upper cushion half portion (22) has a tubular, inflated cushioning area (120) positioned laterally of the occupant's head, characterized by , that the tubular inflated cushioning region (120) has a larger diameter than each of the two filled regions (126, 140) of the tubular inflated ring when viewed in vertical section, and extends further toward the occupant than the tubular inflated ring surrounding the central uninflated region (110) to thereby provide an enlarged cushioning surface (118) for supporting the side of the occupant's head in a side impact. [2] The occupant restraint airbag cushion (16) of claim 1, wherein the enlarged cushioning surface (118) has a bulbous, elliptical shape. [3] The occupant restraint airbag cushion (16) of claim 1, wherein the enlarged cushioning surface (118) is provided by an enlarged, bulbous, filled cushioning region (120), and the size and shape of the enlarged cushioning region (120) are provided by first and second unfilled regions (114, 116) defined by first and second encircles (48, 50) of fasteners provided between the occupant-facing panel (26) and the panel (28) opposite the occupant-facing panel (26). [4] The occupant restraint airbag cushion (16) of claim 3, wherein the attachments are sewing stitches or an adhesive. [5] The occupant restraint airbag cushion (16) of claim 3, wherein the encircles (48, 50) of attachments have a round or an elongated shape. [6] The occupant restraint airbag cushion (16) of claim 3, wherein a series (58) of further fasteners extends between the first and second encircles (48, 50) to further define the enlarged cushion area (120). [7] The occupant restraint airbag cushion (16) of claim 6, wherein the series (58) of further attachments extends in either a generally straight line path between the first and second encircles (48, 50) or a concave downward path or a convex upward path between the first and second encircles (48, 50). [8] The occupant restraint airbag cushion (16) of claim 1, further comprising an upper tether (78) having a lower anchored end and an upper end attached to the upper cushion half portion (22) and overlying the enlarged cushion surface (118) such that the upper tether (78) has a shorter length than the cushion (16) to rotate the upper cushion half portion (22) toward the occupant's head. [9] The occupant restraint airbag cushion (16) of claim 1, further comprising a lower tether (70) having a rear anchored end and a front end attached to the lower cushion half portion (20) such that the lower tether (70) restrains the lower cushion half portion (20) from deflecting away from the occupant. [10] The occupant restraint airbag cushion (16) of claim 1, further comprising an upper tether (78) having a lower anchored end and an upper end attached to the upper cushion half portion (22) and overlying the enlarged cushion surface (118) such that the upper tether (78) is contacted by the occupant's head, and a lower tether (70) having a rear anchored end and a front end attached to the lower cushion half portion (20) such that the upper and lower tethers (78, 70) restrain the upper cushion half portion (22) and the lower cushion half portion (20) against flexion away from the occupant.

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