Product with an airbag cushion for use as a front center airbag

Abstract

Product (50) that includes: an airbag cushion (64) constructed and arranged such that the airbag cushion (64) in a deployed condition (58) provides lateral head, and / or shoulder and / or torso coverage for an occupant (48), wherein the airbag cushion (64) includes an upper chamber (76) and a lower chamber (78), and wherein the lower chamber (78) is constructed and arranged to overlap at least a portion of a center console (52) in a vehicle when the airbag cushion (64) is in the deployed condition (58); characterized in that the airbag cushion (64) includes at least one first seam (94) extending around a portion of the perimeter of the airbag cushion (64) and at least one second seam (110) creating an opening (112) between the upper chamber (76) and the lower chamber (78) in the airbag cushion (64) such that during deployment, an inflator gas inflates the lower chamber (78) at a lower rate than the upper chamber (76); wherein the airbag cushion (64) further comprises a first cushion plate (66), a second cushion plate (68), and a sacrificial material (176) attached to the first cushion plate (66) and the second cushion plate (68) and constructed and arranged to break apart during deployment as the airbag cushion (64) is inflated to retard the flow of gas generator gas through the opening (112).

Description

TECHNICAL FIELD

[0001] The present invention relates to a product with an airbag cushion for use as a front center airbag according to the preamble of claim 1, as known for example from US 2014 / 0 151 984 A1. BACKGROUND

[0002] A vehicle may contain one or more safety restraint devices. For example, US 2007 / 0 284 859 A1 discloses an airbag cushion that is divided by a seam into an upper and a lower chamber, which are connected to each other by an opening. Furthermore, US 2006 / 0 131 847 A1 describes an airbag cushion that has two opposing cushion sections connected by a tear seam, which influences the deployment of the cushion.

[0003] According to the invention, a product with an airbag cushion is provided which has the features of claim 1. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Selected examples of variants within the scope of the invention will be more fully understood from the detailed description and the accompanying drawings, in which: Fig. Figure 1 is a perspective view of an airbag in an inflated condition in accordance with a number of variants. Fig. Figure 2 is a front sectional view of an airbag in an inflated condition in accordance with a number of variants. Fig. Figure 3 is a front sectional view of an airbag in an inflated condition in accordance with a number of variants. Fig. Figure 4 is a front sectional view of an airbag in an inflated condition in accordance with a number of variants. Fig. Figure 5 is a front sectional view of an airbag in an inflated condition in accordance with a number of variants. Fig. Figure 6 is a side view of an airbag cushion assembly in accordance with a number of variations. Fig. Figure 7 is a side view of an airbag cushion assembly in accordance with a number of variations. Fig. Figure 8 is a side view of an airbag cushion assembly in accordance with a number of variations. Fig. 9 is a side view of an airbag cushion assembly in accordance with a number of variations. Fig. 10 is a side view of an airbag cushion assembly in accordance with a number of variations. Fig. Figure 11 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 12 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 13 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 14 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 15 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 16 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 17 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 18 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. Figure 19 is an enlarged view of a lower cushion chamber in accordance with a number of variations. Fig. 20 is a side view of a cushion arrangement in accordance with a number of variations. Fig. Figure 21 is an enlarged view of a tether in accordance with a number of variants. Fig. Figure 22 is a side view of a cushion arrangement in accordance with a number of variations. Fig. Figure 23 is an enlarged view of a tether in accordance with a number of variants. Fig. Figure 24 is an enlarged view of a tether in accordance with a number of variants. Fig. 25 a cross-sectional view along AA from Fig. 24 represents. Fig. Figure 26 is a side view of a cushion arrangement in accordance with a number of variations. Fig. 27 illustrates an enlarged view of a gas generator assembly and mounting bracket attached to a cushion assembly in accordance with a number of variations. Fig. Figure 28 is a top sectional view of an airbag in a seat in accordance with a number of variants. Fig. Figure 29 is a top sectional view of an airbag in a seat in accordance with a number of variants. DETAILED DESCRIPTION OF ILLUSTRATIVE VARIANTS

[0005] The following description of the variants is merely illustrative in nature.

[0006] The Fig. 1-27 show numerous variants that contain a front center airbag 50. Based on Fig. 1, the front center airbag 50 may be constructed and arranged in a number of variations to provide head, shoulder, and / or torso coverage for an occupant 48 during an impact event by deploying adjacent to these body regions. The front center airbag 50 may be constructed and arranged to provide an overlap over a portion of a center console 52 that may be in a vehicle, which may enhance the containment of the front center airbag 50 in a deployed condition 58 by utilizing the center console 52 as a reaction surface for the front center airbag 50.

[0007] Based on Fig. 6-19, in a number of variations, the front center airbag 50 may include a cushion assembly 64 including an upper cushion chamber 76 and at least one lower cushion chamber 78. The cushion assembly 64 may be constructed and arranged such that inflation of the lower cushion chamber 78 with inflator gas may be delayed while the front center airbag 50 is deploying, which may prevent or reduce the likelihood of the front center airbag 50 becoming snagged on the center console 52 during the deployment process as the front center airbag pivots over the center console during the initial phase of deployment and subsequently positions itself between the center console 52 and the adjacent occupant 48.The delayed inflation of the lower cushion chamber 78 may allow that portion of the cushion to pass over the center console 52 in a substantially undeployed state, thus achieving a fully deployed position adjacent the center console 52 after passing over the center console 52 and after the lower cushion chamber is fully inflated. The lower cushion chamber 78 may be constructed and arranged so that the interaction between the cushion assembly 64 and the center console 52 may occur at a location on the center console 52 that may be generally below or forward of the shoulder load point of the occupant 48 of a cushion assembly 64.

[0008] In a number of variations, the cushion assembly 64 may include a first plate 66 forming the inner surface of the cushion assembly 64 and a second plate 68 forming the outer surface of the cushion assembly 64, for which variations are described in Fig. 6-10. The first plate 66 and the second plate 68 may be symmetrical or non-symmetrical and may comprise numerous constant radius or variable radius shapes, including, but not limited to, a circle, an ellipse, an oval-like shape, or an egg-like shape. The first and second plates 66, 68 may each include a taper 72 that may extend downwardly from a rear end 70 of the plate 66, 68 and that may be constructed and arranged to receive an inflator 218, as discussed below. In one variation, the first and / or second plates 66, 68 may comprise a woven material. In a number of variations, the first plate 66 and / or second plate 68 may further include a coating.Any number of coatings may be used, including, but not limited to, a rubberized coating and / or a silicone coating. In a number of variations, one or more reinforcement plates, diffusers, and / or cushion attachments (not shown) may be attached to the first plate 66 and / or the second plate 68, which may increase the strength of the cushion assembly 64 and protect the cushion assembly 64. In another variation, the first plate 66 and the second plate 68 may be woven as a single piece.

[0009] In a number of variations, the first panel 66 and the second panel 68 may be secured together using at least one seam 94, which may be offset around the perimeter of the first panel 66 and the second panel 68 to the end 74 of the taper 72, such that the end 74 of the tapers 72 may remain open so that the inflator 218, as discussed below, may be positioned within this opening and fill the cushion assembly 64 with inflator gas upon deployment. A cushion selvage 96 may remain around the perimeter seam 94. In a number of variations, the perimeter seam 94 may include one or more rows of stitching and / or be woven such that the cushion assembly 64 may be a part. In a number of variations, at least a portion of the perimeter seam 94 may also include a sealant to retain gas within the airbag cushion assembly 64 at the perimeter seam 94.Any number of sealants may be used, including, but not limited to, a rubberized material and / or silicone. In another variation, the circumferential seam 94 may not be sealed.

[0010] In a number of variations, the cushion assembly 64 may further include one or more seams 98, 102, 110, 126, 132, 142, 148, 154, 162, 172 that may be used to control the shape and inflated volume of the cushion assembly 64 in an inflated state 58. The one or more seams 98, 102, 110, 126, 132, 142, 148, 154, 162, 172 may include one or more rows of stitching and / or may be woven into the cushion assembly 64. In a number of variations, the airbag cushion assembly 64 may fill with a gas and inflate within the perimeter seam 94 and around the seams 98, 102, 110, 126, 132, 142, 148, 154, 162, 172 when the front center airbag 50 is deployable. In a number of variations, at least a portion of the seams 98, 102, 110, 126, 132, 142, 148, 154, 162, 172 may include a sealant to further retain gas within the airbag cushion assembly 64.Any number of sealants may be used, including, but not limited to, a rubberized material and / or silicone. In another variation, seams 98, 102, 110, 126, 132, 142, 148, 154, 162, and 172 may be unsealed.

[0011] In a number of variations, the upper cushion chamber 76 may include a central region 82 and an upper region 80 of the cushion assembly 64, and the lower cushion chamber 78 may include a lower region 84 of the cushion assembly 64. In one variation, the upper cushion chamber 76 may include a first inactive region 98 around a portion of the central region 82, creating a first inactive region 100. The first inactive region 100 may be any number of configurations, including, but not limited to, circular, oval, and / or teardrop-shaped. In a number of variations, a second inactive region 102 may extend from the first inactive region 98.In a variation, the second inseam 102 may include a curve or loop 104 outwardly toward the front end 86 of the cushion assembly 64 and then back toward the first inactive region 100 and the rear end 88 of the cushion assembly 64 such that the first inseam 98 and the second inseam 102 together form a general figure six shape with the first inactive region 100 in the lower number six shaped portion, variations of which are disclosed in . Fig. 6-10. The "six" shape construction may reduce the internal stress of the cushion assembly 64 during deployment and may also allow for the use of a thinner cushion material and a thinner sealant at the seams 98, 102. Furthermore, it may reduce the package size of the front center airbag 50 and the cost of the front center airbag 50. Additionally, the second inseam 102 may include a second end 106, which may include a second inactive region 108. The second inactive region 108 may be any number of shapes, including, but not limited to, a teardrop, an oval, or circular, variations of which are also provided in Fig. 6-10 are shown.

[0012] In a variant, the cushion assembly 64, which has a general shape of the number six, may not include a separate lower cushion chamber, for which a variant in Fig. 11 is shown.

[0013] According to the invention, the lower cushion chamber 78 is constructed and arranged such that the lower cushion chamber 78 can be inflated with a gas at a delayed rate during a deployment event compared to the upper cushion chamber 76. In one variation, the lower cushion chamber 78 can be constructed and arranged such that the widest portion 92 of the lower cushion chamber 78 in an inflated state can be near the center of the lower cushion chamber 78. In another variation, the lower cushion chamber 78 can be constructed and arranged such that the widest inflated portion 92 of the lower cushion chamber 78 in an inflated state can be at the rear end 91 of the lower cushion chamber 78, for which variations in Fig. 12 and Fig. 13 are shown.

[0014] The lower cushion chamber 78 may be formed with one or more internal seams 110, 126, 132, 142, 148, 154, 162, which may separate the lower cushion chamber 78 from the upper cushion chamber 76. According to the invention, one or more internal seams 110, 126, 132, 142, 148, 154, 162 and / or the circumferential seam 94 form an opening 112 between the upper cushion chamber 76 and the lower cushion chamber 78, for which variations in Fig. 6-10 and 12-19. The opening 112 may be located at the forward end 86 of the cushion assembly 64 so that gas can enter the lower cushion chamber 78 at a location farther forward than the center of gravity or central region 82 of the cushion assembly 64. The size and / or shape of the opening 112 can help control the delay in inflation of the lower cushion chamber 78 relative to the rest of the cushion. In a number of variations, the opening 112 into the lower cushion chamber 78 can be tapered or narrowed, which can further delay the inflation of gas into the lower cushion chamber 78. The opening 112 may be narrowed using one or more internal seams 110, 126, 132, 142, 148, 154, 162, which may be any number of configurations, including, but not limited to, rounded, teardrop, or a variable radius shape.The length of the constriction or taper of the opening 112 may be increased and / or the width may be decreased, which may further delay the inflation time of the lower cushion chamber 78 by providing a more difficult entry path for the inflation gas to enter the lower cushion chamber 78.

[0015] In one variation, a first inner seam 110 may extend horizontally from the rear end 86 of the cushion assembly 64 from the peripheral seam 94, for which variations in Fig. 6-9 and 12-14. In one variant, the first inner seam 110 may extend approximately over more than half the length of the lower cushion chamber 78, for which variants in Fig. 6-9 and 12-14. A second end 116 of the first inseam 110 may form a first inactive region 118, which may cause one or more portions of the lower cushion chamber 78 to taper downward, which may increase the filling time of the lower cushion chamber 78. The first inactive region 118 may have any number of configurations, including, but not limited to, rounded 120, for which variations are described in Fig. 6, Fig. 7 and Fig. 12, a teardrop shape 122, for which variants in Fig. 8 and Fig. 14, a shape 124 of an elongated circle or oval, for which variants in Fig. 9, or an elongated circle or oval, which may be bent downwards 125, for which a variant is shown in Fig. 13 is shown.

[0016] In another variant, a first inner seam 126 may extend horizontally from the rear end 88 of the cushion assembly 64 from the peripheral seam 94, and a second inner seam 132 may extend horizontally from the front end 86 of the cushion assembly 64 from the peripheral seam 94 approximately opposite the first inner seam 126, for which a variant is disclosed in Fig. 15. The first inseam 126 may extend approximately more than half the length of the lower cushion chamber 78, while the second inseam 132 may extend less than half the length of the lower cushion chamber 78. A second end 128 of the first inseam 126 may include a first inactive region 130, and a second end 134 of the second inseam 132 may include a second inactive region 136. The first and second inactive regions 130, 136 may be any number of configurations, including, but not limited to, rounded, variable radius shaped, or a teardrop shape. In one variation, the first and / or second inactive regions 130, 136 may be downwardly curved.

[0017] In one variant, a first inner seam 142 and a second inner seam 148 can each run horizontally from a rear end 88 of the circumferential seam 94, for which a variant in Fig. 16 and Fig. 17. The first inner seam 142 and the second inner seam 148 may extend a distance from the circumferential seam 94 of the cushion assembly 64. The first inner seam 142 and the second inner seam 148 may each extend more than half the length of the lower cushion chamber 78. The first inner seam 142 and the second inner seam 148 may be approximately parallel to one another. The first and second inner seams 142, 148 may form a first tube section 138 and a second tube section 140, which may act as first and second lower chambers. In one variation, the first inner seam 142 and the second inner seam 148 may extend the same distance, for which a variation is shown in Fig. 16. In another variant, the first inner seam 142 can extend further than the second inner seam 148, for which a variant is shown in Fig. 17. A second end 144 of the first inseam 142 may include a first inactive region 146, and a second end 150 of the second inseam 148 may include a second inactive region 152. The first and second inactive regions 146, 152 may be any number of configurations, including, but not limited to, a variable radius shape or a rounded shape. The first and second inactive regions 146, 152 may be the same shape or may include different shapes. Furthermore, the position of the first and second inactive regions 146, 152 in the lower cushion chamber 78 may be varied via the Fig. 16 and Fig. 17 locations shown may be changed.

[0018] In another variant, the inner seam 154 may extend horizontally from a rear portion 88 of the circumferential seam 94, it may be saddled or curved 156 approximately centrally to the lower cushion chamber 78, it may continue horizontally for a distance toward the front end 86 of the cushion assembly 64, it may then extend downwardly for a distance at an angle toward the front end 86 of the cushion assembly 64, and it may then extend horizontally toward the rear end 88 of the cushion assembly 64, for which a variant in Fig. 18. This approach positions the smallest cross-section of the opening 112 in the front lower region 163 of the lower cushion chamber 78. In a number of variations, the dip or curve 156 in the inseam 154 above the lower cushion chamber 78 may provide a wider and more rigid cushion cross-section, which may prevent or reduce flexion of the cushion assembly 64 in the deployed state. The inseam 154 may extend for a length greater than half of the lower cushion chamber 78. A second end 58 of the inseam 154 may include an inactive region 160. In one variation, the inactive region 160 may comprise an elongated teardrop shape.

[0019] In another variant, an inner seam 162 may extend horizontally from a rear end 88 of the circumferential seam 94, it may be saddled or curved 164 approximately in the middle of the lower cushion chamber 78, it may continue horizontally for a distance towards the front end 86 of the cushion assembly 64, it may extend downwardly for a distance at an angle towards the rear end 88 of the cushion assembly 64, and it may then extend horizontally towards the rear end 88 of the cushion assembly 64, for which a variant in Fig. 19. This approach positions the smallest cross-section of the opening 112 at the front upper region 165 of the lower cushion chamber 78. In a number of variations, the dip or curve 164 in the inseam 162 above the lower cushion chamber 78 can provide a wider and more rigid cushion cross-section, which can prevent or reduce flexion of the cushion assembly 64 in a deployed condition. The inseam 162 can extend for a length greater than half the length of the lower cushion chamber 78. A second end 166 of the inseam 162 can include an inactive region 168. The inactive region 168 can be any number of shapes, including, but not limited to, an elongated teardrop shape.

[0020] In another variation, the peripheral seam 94 of the lower cushion chamber 78 may be a circular sector-like shape 170 and include an inner seam 172 that may surround a portion of the lower cushion chamber 78 and form an inactive region 174. The inactive region 174 may be any number of shapes, including, but not limited to, circular, oval, or kidney-shaped, a variation of which is disclosed in Fig. 10. In yet another variant, a small opening 112 may be located on each side of an inactive region 170, for which a variant is shown in Fig. 10 is shown.

[0021] According to the invention, a sacrificial material 176 is located within the lower cushion chamber 78, for which variants in Fig. 12, Fig. 13 and Fig. 15. The sacrificial material 176 temporarily secures the first plate 66 and the second plate 68 together and may be adjacent to the opening 112. During a deployment condition 58, gas may enter the cushion assembly 64 and cause the sacrificial material 176 to separate, which may take time to occur and may subsequently further increase the time required for the gas to reach the opening 112 and inflate the lower cushion chamber 78. The sacrificial material 178 may comprise any number of materials, including, but not limited to, one or more rubberized materials and / or silicone dots.

[0022] Based on Fig. 2-5 and 20-25, the cushion assembly 64 may, in a number of variations, include one or more outer tethers 178, 184, 186, 188, 190, 196, 202, 208 that may help guide the trajectory and kinematics of the front center airbag 50 as it is deployed from a collapsed to a deployed state 58. The one or more outer tethers 178, 184, 186, 188, 190, 196, 202, 208 may be constructed and arranged to guide the trajectory of the lower cushion chamber 78 above the center console 52 during a deployed condition 58, and may further position the lower cushion chamber 78 adjacent the center console 52 when the lower cushion chamber 78 passes over the top of the center console 52 and when the lower cushion chamber 78 fully fills.

[0023] In one variation, a first outer tether 178 may be located on the outer side 60 of the cushion assembly 64 and may extend from the cushion selvedge 96 or from another attachment location at the rear end 88 of the cushion assembly 68 to a front end 86 of the cushion assembly 64. In one variation, the first outer tether 178 may be attached to the front end 86 of the cushion assembly 64 and may extend approximately horizontally to the rear end 88 of the cushion assembly 64 and may be attached at or near the rear end 88 of the cushion assembly 64 or to a cushion sleeve 224, a variation of which is disclosed in Fig. 20. The first outer tether 178 may include a length shorter than the length of the cushion assembly 64, which in an inflated state may be below the first outer tether 178 such that the lower cushion chamber 78 may curve outward toward the occupant 48 when inflated, and the effective tether length may be shorter than the cushion length. The first outer tether 178 may be attached to the cushion assembly 64 in any number of variations, including, but not limited to, sewing the first tether 178 to the cushion selvage 96 using one or more stitching lines or by having the tether 178 integrally woven into the cushion assembly 68. In a number of variations, the first outer tether 178 may also be attached to an inactive region 100 in the upper cushion chamber 76.The first outer tether 178 may be configured in any number of variations, including, but not limited to, routing the outer tether 178 through one or more slots 180 that may be located in the inactive region 100, variations of which are described in . Fig. 20, Fig. 22 and Fig. 26, and / or sewing 182 the first tether 178 to the inactive area 100, for which a variant is shown in Fig. 21, be attached to the inactive region 100.

[0024] In a number of variations, a second outer tether 184 may be attached to the outer side 60 of the cushion assembly 64, a variation of which is shown in Fig. 20. In a variant, the second outer tether 184 may extend approximately vertically upward from the cushion selvedge 96 at the lower end 90 of the cushion assembly 64 to the inactive region 100 in the upper cushion chamber 76, a variant of which is also shown in Fig. 20. The second outer tether 184 may comprise a length that may be less than that of the cushion assembly 64, which may be located below the second outer tether 184 when the cushion assembly 64 is in an inflated state 59, which may cause the lower cushion chamber 78 to rotate outwardly 60 toward the occupant 48, a variation of which is shown in Fig. 3 is shown.

[0025] In a variation, the second outer tether 184 may be constructed and arranged such that the lower cushion chamber 78 is significantly angled toward the occupant 48 and extends in an approximately horizontal direction, which may create clearance from any number of interior vehicle trim components, including, but not limited to, a center console 52.

[0026] In another variation, the second outer tether 184 may have a length that may be the same as that of the cushion assembly 64 in an inflated state 95, which may provide a tensile load path that may prevent or reduce flexion of the lower cushion chamber 78 when the cushion assembly 64 may be pushed by an occupant 48 toward the center console 52. The second outer tether 184 may be attached in any number of variations, including, but not limited to, one or more stitching lines 182 to the cushion selvedge 96 and to the first inactive region 100 in the upper cushion chamber 76, or may be woven as a single piece.

[0027] In another variant, the second outer tether 186 may extend upwardly at an angle toward the rear end 88 of the cushion assembly 64, for which variants in Fig. 6-10. In a variant, the second outer tether 186 may extend from the cushion selvedge 96 at the lower end 90 of the cushion assembly 64 to the cushion selvedge 96 at the rear end 88 of the cushion assembly 64, for which a variant is shown in Fig. 6. In another variation, the second outer tether 186 may extend from a first inner seam 110 in the lower cushion chamber 78 to the cushion selvedge 96 at the rear end 88 of the cushion assembly 64, for which variations are disclosed in Fig. 7-10. The second outer tether 186 may be attached to the cushion assembly 64 in any number of variations, including, but not limited to, one or more stitching lines 182 or may be woven in one piece.

[0028] In another variant, a third outer tether 188 may be attached to the inner side 62 of the cushion assembly 64, for which a variant is described in Fig. 22. The third outer tether 188 may extend approximately vertically upward from the cushion selvedge 96 at the lower end 90 of the cushion assembly 64 to the inactive region 100 in the upper cushion chamber 76. The third outer tether 188 may comprise a length that may be less than that of the cushion assembly 64 adjacent to the third outer tether 188 when the cushion assembly 64 is in an inflated state 59, which may cause the lower cushion chamber 78 to rotate inwardly toward the center console 52, a variation of which is shown in Fig. 5. In another variation, the third outer tether 188 may comprise a length that may be less than the cushion assembly 64, which may be adjacent to the third outer tether 188 when the cushion assembly 64 is in an inflated state 59, which may cause the lower cushion chamber 78 to rotate onto the center console 52, a variation of which is shown in Fig. 4. The third outer tether 188 may be constructed and arranged so that the cushion assembly 64 may include a higher volume or thickness in the lower cushion chamber 78, which may reduce the loading of the occupant 48 into numerous vehicle interior trim components, including, but not limited to, a center console 52. The third outer tether 188 may also prevent or reduce lateral movement of an occupant 48 in a crash event. In another variation, the third outer tether 188 may have a length that may be the same length as that of the cushion assembly 64 in an inflated state, which may resist flexion of the lower cushion chamber 78 as the cushion assembly 64 is pushed by an occupant 48 toward the center console 52, a variation of which is disclosed in Fig. 2. The third outer tether 188 may be attached to the cushion selvedge 96 and the inactive region 100 in any number of variations, including, but not limited to, one or more stitching lines 182, and may be woven in one piece.

[0029] In another variation, a series of outer tethers 190, 196, 202 may be located on the outer side 60 of the cushion assembly 64, forming a zigzag pattern or “Z” shape, a variation of which is disclosed in Fig. 23. A first end 192 of the fourth outer tether 190 may be attached to the selvage 96 at a front end 86 of the cushion assembly 64 and may extend approximately horizontally toward the rear end 88 of the cushion assembly 64, and the second end 194 may be attached to the cushion selvage 96 and / or to a cushion sleeve 224 at the rear end 88 of the cushion assembly 64. A first end 198 of a fifth outer tether 196 may be attached at or near the second end 194 of the fourth outer tether 190 and may extend downwardly at an angle to the front end 86 of the cushion assembly 64, and the second end 200 may be attached to the cushion selvage 96 at the front end 96 of the cushion assembly 64.A first end 204 of a sixth outer tether 202 may be attached at or near the second end 200 of the fifth outer tether 196 and may extend approximately horizontally toward the rear end 88 of the cushion assembly 64, and a second end 206 may be attached at or near the cushion selvedge 96 at the rear end 88 of the cushion assembly 64. In one variation, the fourth, fifth, and sixth tethers 190, 196, 202 may be separate components. In other variations, the fourth, fifth, and / or sixth tethers 190, 196, 202 may comprise a single tether or two tethers. The tethers 190, 196, 202 may be attached to the cushion assembly 64 in any number of variations, including, but not limited to, one or more stitching lines 182 and may be woven in one piece.

[0030] In another variant, a seventh outer tether 208 may extend on the outer side 60 of the cushion assembly 64 adjacent to the lower cushion chamber 78 from the front end 86 of the cushion assembly 64 to the rear end 88 of the cushion assembly 64, a variant of which is described in Fig. 24-25. In a number of variations, the seventh outer tether 208 may be of such a length that its length may be shorter than that of the lower chamber 78, for which a variation is shown in Fig. 25 is shown.

[0031] It is noted that the outer tether configurations illustrated above may be used alone or together in any number of variations. In a number of variations, the outer tether configurations may control the position of the lower cushion chamber 78 such that the lower cushion chamber 78 is parallel to the center console 52, a variation of which is described in Fig. 2, is bevelled outwards in the direction of the occupant 48, for which a variant in Fig. 3 is shown, is bevelled inwards towards the center console 52, for which a variant in Fig. 5, on the center console 52, for which a variant in Fig. 4, or partially on the center console 52, with or without a degree of bevel (not shown).

[0032] It is noted that the seats may move up and down in a number of variations and that the center console 52 may be designed to be vertically fixed so that, depending on the vertical position of the seat and the cushion shape, various vertical and lateral relationships between the airbag cushion (attached to the seat) and the center console 52 may be possible.

[0033] Based on Fig. 26, a protective layer 212 may be attached to the cushion assembly 64 in a number of variations. The protective layer 212 may cover a portion of the inner surface 62 of the cushion assembly 64. In one variation, the protective layer 212 may cover approximately the lower quarter to the lower half of the inner surface 62 of the cushion assembly 64. The protective layer 212 may comprise any number of materials, including, but not limited to, a woven fabric. The protective layer 212 may include a coating on its outer surface. Any number of coatings, including, but not limited to, silicon and / or silicone, may be used. The protective layer 212 may be attached to the cushion assembly 64 in any number of variations, including, but not limited to, one or more stitching lines 182 that may extend around a portion of the protective layer 212, the cushion selvedge 96, and the first inactive region 100.The protective layer 212 may protect the front center airbag 50 from objects that may be adjacent to the front center airbag 50 in a deployment state 58, including, but not limited to, a seat, a center console 52, a transmission selector, a parking brake, and / or other airbag components. The protective layer 212 may also act as a stiffening element for the cushion assembly 64 in a deployment state 58 when an occupant 48 may load the cushion assembly 64 while the occupant 48 may move toward the center console 52 and / or across the center console 52.

[0034] In a number of variations, the cushion assembly 64 may be secured to a mounting bracket 214 and to a gas generator assembly 216 via one or more clamps 222, a variation of which is shown in Fig. 27. The gas generator assembly 216 may include a gas generator 218 and a wiring harness 220, a variation of which is also shown in Fig. 27. The wiring harness 220 may be operatively connected to an airbag sensor (not shown), which may send a signal to the inflator 218 to deploy if any number of vehicle conditions occur, including, but not limited to, a crash event. The airbag inflator 218 may be operatively connected to an electronic control unit (ECU) (not shown), which may include a sensing logic system that may be used to determine whether or not crash events are occurring. If a crash event is detected that occurs in a predetermined direction above a certain deployment threshold, the ECU may then send a signal to the inflator 218 to deploy the front center airbag 50.

[0035] In a number of variations, the cushion assembly 64 may further include a sleeve 224 that may be constructed and arranged to receive the mounting bracket 214, the one or more clamps 222, the mechanical seat mounting fasteners 234, and / or a portion of the gas generator assembly 218, for which variations are described in Fig. 20 and Fig. 27. The gas generator assembly 216 may be attached to the cushion assembly 64 such that the gas generator 218 may be in a position to fill the cushion assembly 64 with gas to inflate the cushion assembly 64.

[0036] In a number of variations, the cushion assembly 64 can be folded to a compact size 226, for which variations in Fig. 28-29. The fold 226 of the cushion assembly 64 may also assist in the trajectory of the front center airbag 50 in a deployment state 58. Any number of folds 226 may be used, including, but not limited to, a roll fold, a fan fold, or a combination of a roll fold and a fan fold.

[0037] In a number of variations, a cover 228, 230 may surround at least a portion of the folded front center airbag 50. The cover 228, 230 may be of any number of types and configurations, including, but not limited to, a flexible shell 228, a variation of which is described in Fig. 28, or a more rigid capsule 230, for which a variant is shown in Fig. 29. In one variation, the capsule 230 may include a portion of a discrete deployment flap 242, as discussed below. The cover 228, 230 may comprise a single, continuous component or may include multiple components.

[0038] In a number of variants, the front center airbag 50 may be mounted on the inside 244 of the driver or passenger seat frame 232, for which variants in Fig. 28-29. The front center airbag 50 may be attached to the seat frame 232 in any number of ways, including, but not limited to, one or more mechanical fasteners 234.

[0039] In a number of variations, the front center airbag 50 may be concealed within the seat 236. During deployment, the front center airbag 50 may deploy through a tear seam 238 on the seat 236 and / or may deploy through a deployment duct 240 within the seat 236, for which variations are available in Fig. 28. In another variant, the front center airbag 50 can deploy through a discrete deployment flap 242, for which a variant is shown in Fig. 29. The discrete deployment flap 242 may be integrated into the seat 236 or may be part of the front center airbag 50.

Claims

[1] Product (50) which includes: an airbag cushion (64) constructed and arranged such that the airbag cushion (64) in a deployed condition (58) provides lateral head, and / or shoulder and / or torso coverage for an occupant (48), wherein the airbag cushion (64) includes an upper chamber (76) and a lower chamber (78), and wherein the lower chamber (78) is constructed and arranged to overlap at least a portion of a center console (52) in a vehicle when the airbag cushion (64) is in the deployed condition (58); characterized by , that the airbag cushion (64) includes at least one first seam (94) extending around a portion of the perimeter of the airbag cushion (64) and at least one second seam (110) creating an opening (112) between the upper chamber (76) and the lower chamber (78) in the airbag cushion (64) such that during deployment, an inflator gas inflates the lower chamber (78) at a lower rate than the upper chamber (76); wherein the airbag cushion (64) further comprises a first cushion plate (66), a second cushion plate (68), and a sacrificial material (176) attached to the first cushion plate (66) and the second cushion plate (68) and constructed and arranged to break apart during deployment as the airbag cushion (64) is inflated to retard the flow of gas generator gas through the opening (112). [2] The product (50) of claim 1, wherein the opening (112) is downwardly tapered to further delay entry of the inflator gas into the lower chamber (78) and / or is located at the front of the airbag cushion (64) away from the inflator location. [3] The product (50) of claim 1, wherein the at least one second seam (110) includes an inactive region (118) to reduce stress at the opening (112). [4] The product (50) of claim 1, wherein the lower chamber (78) is constructed and arranged such that the widest portion (92) of the lower chamber (78) in an inflated condition (59) is near a center of the lower chamber (78) and / or near a rear end (91) of the lower chamber (78). [5] The product (50) of claim 1, wherein the airbag cushion (64) further comprises at least one tether (178, 188) constructed and arranged to control the trajectory of the lower chamber (78) during deployment. [6] The product (50) of claim 5, wherein a length of the at least one tether (178, 188) in an inflated state (59) is less than a length of the airbag cushion (64) below the at least one tether (178, 188), such that in the inflated state (59) the at least one tether (178, 188) causes the lower chamber (78) to rotate toward the at least one tether (178, 188). [7] The product (50) of claim 5, wherein a length of the at least one tether (188) is approximately the same length as that of the airbag cushion (64) in an inflated condition (59) below the at least one tether (188) such that the airbag cushion (64) resists flexion of the lower chamber (78) in the deployed condition (58). [8] Product (50) according to claim 5, wherein the at least one tether (178) is attached to an inner side (62) and / or to an outer side (60) of the airbag cushion (64) and extends approximately horizontally from a front end (86) of the airbag cushion (64) to a rear end (88) of the airbag cushion (64).

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