How to assemble a suction airbag cushion assembly

Abstract

A method for assembling an airbag cushion assembly for drawing in ambient air. The inflator modules (330, 430) can, in some cases, be crimped onto the inflator hub (338, 438) without using any fasteners and / or releaseable coupling features.

Description

Technical Field

[0001] (Cross-Reference to Related Applications) This application is a continuation-in-part of pending Application No. 18 / 207,123, filed on June 7, 2023 and entitled "SYSTEMS AND METHODS FOR IMPROVED AIRBAG ASPIRATION", which is a continuation of Application No. 17 / 453,178, filed on November 1, 2021 and also entitled "SYSTEMS AND METHODS FOR IMPROVED AIRBAG ASPIRATION". Each of the foregoing applications is incorporated herein by reference in its entirety. Summary of the Invention

[0002] Various improvements in vehicle technology, such as for autonomous vehicles, may require changes to the method of operation of airbag assemblies. For example, larger airbags may be used in some autonomous vehicles, or other newer vehicles. This may be necessary, for example, due to the increased distance between the airbag module and a vehicle occupant. It is further contemplated that in some systems, a single cushion may be used to provide protection for multiple occupants.

[0003] However, existing aspirated airbag assemblies suffer from a number of disadvantages, such as being large, bulky, and / or complex, often requiring many different components and valve mechanisms. Such existing assemblies are often complex and / or more difficult to assemble than necessary, further adding to cost.

[0004] Furthermore, while other aspiration systems have been used, they are often less efficient than they could ideally be and have aspiration rates that can be improved.

[0005] Accordingly, the inventors have determined that it would be desirable to provide systems and methods that overcome the aforementioned limitations and / or one or more other limitations of the prior art. In some embodiments, the inventive concepts disclosed herein may enable the provision of assemblies that improve suction efficiency by, for example, providing expansion ports for generating suction in multiple rows on each expansion conduit, and / or forming ports having one or more feature portions to improve efficiency. For example, some embodiments may include expansion ports having a divergence angle and / or Prandtl-Meyer feature portion for directing an ultrasonic plume into a region designed to improve gas velocity, generate lower pressure, and / or improve suction efficiency.

[0006] In some embodiments, more specific examples of suction airbag cushion assemblies, the assembly may comprise an airbag cushion and may be part of a housing and / or airbag package comprising the airbag cushion. The suction housing may be fluid-coupled to the airbag cushion and / or the airbag cushion housing. The suction housing may include a suction inlet configured to allow the intake of ambient air into the airbag cushion during inflation of the airbag cushion. The assembly may further include an inflation module comprising an inflator and an inflation conduit fluid-coupled to the inflator. The inflation conduit may have a long axis and may be configured to deliver inflation gas from the inflator into the airbag cushion through a plurality of suction ports. One or more of the inflation conduits (each in some embodiments) may have at least two rows of suction ports.

[0007] In some embodiments, each of the suction ports in the first row of at least two rows of suction ports is offset from the center of the expansion conduit, with the center measured perpendicular to the long axis toward the first side of the expansion conduit adjacent to the first suction opening of the suction inlet. In some such embodiments, each of the suction ports in the second row of at least two rows of suction ports is on the opposite side of the first side and offset from the center toward the second side of the expansion conduit adjacent to the second suction opening of the suction inlet.

[0008] In some embodiments, each of the suction ports in the first row may be angled toward the first side of the expansion conduit, and / or each of the suction ports in the second row may be angled toward the second side of the expansion conduit.

[0009] In some embodiments, each of the suction ports among a plurality of suction ports may have a flared distal portion. In some such embodiments, the flared distal portion may have an angled surface that is angled toward a vertical direction at least substantially corresponding to the direction of arrival of ambient air through the suction inlet during deployment. In some such embodiments, the angled surface may be parallel to the vertical direction, or at least substantially parallel.

[0010] In some embodiments, the angled surface may define an angle of about 25 degrees with respect to each adjacent proximal portion of the suction port.

[0011] In some embodiments, the suction ports of at least two rows may comprise a first row and a second row. In some such embodiments, the first row may comprise suction ports offset from the suction ports of the second row such that each of the suction ports of the first row is positioned along the long axis of the expansion conduit adjacent to the suction ports of the second row.

[0012] Some embodiments may further include a plurality of expansion conduits fluidly coupled to the inflator, each of which expansion conduits includes a long axis, and each of which expansion conduits is configured to deliver expansion gas from the inflator into the airbag cushion through a plurality of suction ports. In some such embodiments, each of which expansion conduits includes at least two rows of suction ports.

[0013] In another example of a suction airbag cushion assembly according to several embodiments, the assembly may comprise an airbag cushion and a housing having a suction inlet configured to allow ambient air to be received into the airbag cushion during inflation. The assembly may further comprise an inflation module having an inflation conduit configured to deliver inflation gas from an inflator, the inflation conduit having a plurality of inflation ports configured to draw ambient air through the suction inlet when the inflator is in operation. In some embodiments, at least a subset of the plurality of inflation ports may comprise a polyfaceted port. For example, in some embodiments, a polyfaceted port may comprise a first portion that directs the inflation gas away from a perpendicular direction at least substantially corresponding to the direction in which ambient air arrives through the suction inlet during deployment, and a second portion that is angled relative to the first portion in a direction angled perpendicular to the first portion.

[0014] Some embodiments may further include a valve assembly having at least one valve flap, the valve assembly configured to open at least one valve flap when the inflator is in operation, and the valve assembly further configured to close at least one valve flap after the airbag cushion is inflated to prevent air and inflation gas from escaping through the suction inlet after the airbag cushion is inflated.

[0015] In some embodiments, the expansion conduit may comprise a first row of expansion ports adjacent to a first side of the expansion conduit, and a second row of expansion ports adjacent to a second side of the expansion conduit opposite the first side. In some such embodiments, the first row may comprise suction ports offset from and / or staggered with the suction ports of the second row, such that each suction port of the first row is positioned along the long axis of the expansion conduit adjacent to the suction ports of the second row.

[0016] In some embodiments, the second portion can at least partially define a widening feature that expands the expansion port in the distal portion of the expansion port.

[0017] In some embodiments, the second portion may be at least substantially parallel to the vertical direction.

[0018] In yet another example of a suction airbag cushion assembly according to several embodiments, the assembly may comprise an airbag cushion and a suction inlet configured to allow ambient air to be drawn into the airbag cushion during inflation of the airbag cushion. The assembly may further comprise a plurality of inflation conduits. Each of the plurality of inflation conduits may comprise a first row of inflation ports and a second row of inflation ports. Preferably, each of the first row of inflation ports has an angled surface angled toward the second row of inflation ports, and each of the second row of inflation ports has an angled surface angled toward the first row of inflation ports. The assembly may further comprise a valve assembly comprising at least one valve configured to open to allow ambient air to be drawn through the suction inlet and to close after inflation of the airbag cushion.

[0019] In some embodiments, one or more of the angled surfaces (preferably each) have enlarged sizes for their respective expansion ports.

[0020] In some embodiments, each angled surface extends in a direction toward the adjacent and / or proximal portions of its respective port which are at least substantially parallel to the vertical direction, and the vertical direction is at least substantially perpendicular to a plane which extends through each longitudinal axis of each of the plurality of expansion conduits. In some such embodiments, each angled surface may extend at an angle of about 25 degrees from the adjacent surface of its respective expansion port.

[0021] In some embodiments, each of the expansion ports may extend at least partially at an angle of about 25 degrees from a direction at least substantially parallel to the vertical, and the vertical direction is at least substantially perpendicular to a plane extending through each longitudinal axis of each of the plurality of expansion conduits.

[0022] In one example of a method for assembling a suction airbag cushion assembly in several implementation configurations, the method may include inserting at least a portion of the inflator module into the inflator hub of the suction airbag cushion assembly. In some implementation configurations, the inflator module may comprise an inflator and an inflator flange. The method may further include crimping the inflator flange onto the inflator hub.

[0023] In some implementations, the inflator flange may comprise a cylindrical plate coupled to the inflator. In some such implementations, the inflator hub may comprise a cylindrical recess. Therefore, the step of inserting at least a portion of the inflator module into the inflator hub may, in some such implementations, include extending the inflator into the cylindrical recess and extending the inflator flange around the outer surface of the inflator hub.

[0024] In some implementations, the step of crimping the inflator flange onto the inflator hub may comprise crimping a cylindrical plate onto the outer surface of the inflator hub around the entire circumference, or at least substantially the entire circumference, of the cylindrical plate. In some embodiments, the crimping may be performed in a crimping groove, such as an annular groove formed around a portion of the inflator hub.

[0025] In some implementations, the step of crimping the inflator flange onto the inflator hub may comprise fixedly coupling the inflator module to the inflator hub without using any fasteners and / or without using any releasable coupling elements and / or features.

[0026] In some implementations, the step of crimping the inflator flange onto the inflator hub may comprise deforming the inflator flange against a protruding collar of a metal ring.

[0027] Some implementations may further comprise coupling a crimping facilitating element, such as a ring or a tube, to the inflator hub. In some such implementations, the step of crimping the inflator flange onto the inflator hub may comprise crimping the inflator flange onto a portion of the crimping facilitating element. In some embodiments and implementations, the inflator flange may comprise a metal inflator flange.

[0028] In some implementations, the inflator hub may comprise a slot such as a cylindrical slot, and may further comprise inserting a crimping facilitating element such as a ring into the slot. Accordingly, in some such implementations, the step of crimping the inflator flange onto the inflator hub may comprise crimping the inflator flange onto a portion of the crimping facilitating element, which in some cases thereby crimps or otherwise presses the crimping facilitating element against a portion of the inflator hub.

[0029] In some implementations where the crimping promoting element includes a ring, the ring may comprise a metal ring.

[0030] In some implementations, the inflator flange may comprise a metallic material, either in whole or in part.

[0031] In some implementations where the crimping promoting element includes a ring or a tube, the ring may be provided with a plurality of holes. In some such implementations, the method may further comprise melting or otherwise forming a plastic material in at least a subset of the plurality of holes to fixedly couple the ring to the inflator hub. In some implementations, the plastic material may be melted and / or molded to provide a plurality of securing points between the ring, the inflator hub, and the inflator flange.

[0032] Some implementations may comprise overmolding a plastic material in at least a subset of the plurality of holes to fixedly couple the ring / tube to the inflator hub. In some implementations, the metal ring or tube may be positioned at least partially between the inflator hub and the inflator flange. In some such implementations, the inflator flange may be crimped onto the metal ring with a portion of the metal ring / tube deformed against a portion of the inflator hub. In some cases, the crimping may be performed around a protruding collar of the ring / tube.

[0033] In another specific example of a suction airbag cushion assembly, the assembly may include a housing configured to allow ambient air to be drawn into the airbag cushion during inflation of the airbag cushion. The assembly may further include an inflator module comprising an inflator hub, an inflator, and an inflator flange coupled to the inflator hub without the use of any fasteners to permanently connect the inflator to the inflator hub. In some embodiments, the inflator flange may be coupled to the inflator hub without any fasteners and without any releaseable coupling elements such as coupling prongs.

[0034] Some embodiments may further include a metal ring that can be positioned at least partially between the inflator hub and the inflator flange. In some embodiments, the inflator flange may be pressed against the metal ring, and in some cases, a portion of the metal ring is deformed in contact with a portion of the inflator hub.

[0035] In some embodiments, the inflator flanges may be crimped to the inflator hub with or without a metal ring between them.

[0036] Some embodiments may further include a plurality of elongated expansion conduits configured to deliver expansion gas from an inflator. Each of the expansion conduits may have a plurality of expansion ports, each of which may be configured to draw ambient air into the airbag cushion when the inflator is activated.

[0037] In another example of a method for assembling an airbag cushion assembly, the method may include inserting at least a portion of the inflator module into the inflator hub of the airbag cushion assembly. The inflator module may comprise an inflator and an inflator flange. The method may further include crimping the inflator flange onto the inflator hub.

[0038] In some implementations, the airbag cushion assembly may include a suction airbag cushion assembly configured to use an inflator to draw ambient air into the airbag cushion during inflation.

[0039] Some implementations may further include connecting the metal ring to the inflator hub. In some such implementations, the step of connecting the metal ring or tube to the inflator hub may include extending the metal ring / tube over the inflator hub. In other implementations, the step of connecting the metal ring or tube to the inflator hub may include inserting the metal ring into a slot formed in the inflator hub.

[0040] In some implementations, the step of connecting the metal ring / tube to the inflator hub may include inserting the metal ring onto the outer surface of the inflator hub.

[0041] Some implementations may further include overmolding a metal ring / tube onto the inflator hub.

[0042] In some embodiments and configurations, the metal ring may have a protruding collar. In some such configurations, the step of crimping the inflator flange to the inflator hub may include deforming the inflator flange relative to the protruding collar of the metal ring.

[0043] Features, structures, steps, or properties disclosed herein in relation to one embodiment may be combined in any preferred manner in one or more alternative embodiments. [Brief explanation of the drawing]

[0044] With reference to the drawings, non-limiting and non-exclusive embodiments of the present disclosure, including various embodiments thereof, will be described. [Figure 1] Figure 1 is a perspective view of a suction airbag inflation assembly according to several embodiments. [Figure 2] Figure 2 is a cross-sectional view of the suction airbag inflation assembly shown in Figure 1. [Figure 3] Figure 3 is an enlarged cross-sectional view illustrating a preferred divergence angle feature of a suction port for improving suction efficiency. [Figure 4] Figure 4 is a perspective view of a suction airbag inflation assembly according to another embodiment. [Figure 5A] Figure 5A depicts an alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly. [Figure 5B] Figure 5B depicts an alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly. [Figure 5C] Figure 5C depicts an alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly. [Figure 6A] Figure 6A is a cross-sectional view of the crimped portion of the suction airbag inflation assembly shown in Figures 5A to 5C. [Figure 6B] Figure 6B is a cross-sectional view of the crimped portion of the suction airbag inflation assembly shown in Figures 5A to 5C. [Figure 7A] Figure 7A depicts another alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly and features a ring structure to facilitate the crimping procedure. [Figure 7B] Figure 7B depicts another alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly and features a ring structure to facilitate the crimping procedure. [Figure 7C] Figure 7C depicts another alternative embodiment in which the inflator module is crimped to the inflator hub of the suction airbag inflation assembly and features a ring structure to facilitate the crimping procedure. [Figure 8A] Figure 8A is a cross-sectional view of the crimped portion of the suction airbag inflation assembly shown in Figures 7A to 7C. [Figure 8B]Figure 8B is a cross-sectional view of the crimped portion of the suction airbag inflation assembly shown in Figures 7A to 7C. [Modes for carrying out the invention]

[0045] Detailed descriptions of apparatus, systems, and methods consistent with various embodiments of this disclosure are provided below. While several embodiments are described, it should be understood that this disclosure is not limited to any particular embodiment disclosed, but rather encompasses a number of alternative forms, modifications, and equivalents. In addition, while numerous specific details are given in the following description to provide a complete understanding of the embodiments disclosed herein, some embodiments can be implemented without some or all of these details. Furthermore, for clarity and to avoid unnecessarily obscuring this disclosure, certain technical documents known in the relevant art are not described in detail.

[0046] As used herein, the term “substantially” refers to the complete or near-complete degree or extent of an action, characteristic, attribute, state, structure, item, or result that functions as indicated. For example, an object that is “substantially” cylindrical or “substantially” vertical means that the object / characteristic is either cylindrical / vertical or nearly cylindrical / vertical to produce the same or nearly the same function. The exact degree of permissible deviation provided by this term may depend on the specific context. The use of “substantially” is equally applicable when used in a negative implication to refer to the complete or near-complete absence of an action, characteristic, attribute, state, structure, item, or result. For example, a structure that “substantially” lacks a bottom either completely lacks a bottom or nearly completely lacks a bottom to produce substantially the same effect as if the bottom were completely lacking.

[0047] Similarly, as used herein, the term “about” is used to provide flexibility to the endpoints of a numerical range by providing that a given value can be “just above” or “just below” an endpoint while still achieving the function associated with the range.

[0048] Apparatus, methods, and systems disclosed herein relate to suction airbag cushion assemblies configured to inflate larger airbag cushions, such as airbag cushions for multiple occupants, airbag cushions for autonomous vehicles, or pedestrian airbag cushions, using ambient air, in some cases together with an expansion gas. Various embodiments disclosed herein may provide, for example, unique features for improving the coupling mechanisms, components, and / or functions of such assemblies.

[0049] Embodiments of the disclosed herein can be best understood by reference to the drawings, and similar parts may be designated by similar numbers. It will be readily apparent that the components of the disclosed embodiments can be arranged and designed in a wide variety of different configurations, as generally described and illustrated in the drawings herein. Accordingly, the following detailed description of embodiments of the apparatus and methods of the disclosed herein is not intended to limit the scope of the disclosure as claimed, but merely to represent possible embodiments of the disclosure. In addition, unless otherwise specified, the steps of the method do not necessarily have to be performed in any particular order, nor do they necessarily have to be performed sequentially, nor do the steps have to be performed only once. Further details regarding specific preferred embodiments and implementations are described herein in more detail with reference to the accompanying drawings.

[0050] Figure 1 depicts a suction airbag cushion assembly 100. The suction airbag cushion assembly 100 comprises an airbag cushion package 110, which includes an airbag cushion 124 positioned and configured to deploy from there (not shown in Figure 1; see Figure 2). The suction airbag cushion assembly 100 further comprises a suction housing 120 coupled to the airbag cushion package 110. The suction housing 120 has an opening on the open side and / or an opening on its upper side for receiving the airbag cushion and / or for coupling and / or receiving the airbag cushion package 110. The suction airbag cushion assembly 100 may be attached to the suction housing 120 by an elongated rail 113 to hold the airbag cushion 124 in place for packaging and deployment. On the opposite side of this opening, the suction housing 120 has a suction inlet configured to allow ambient air to be drawn into the airbag cushion during inflation.

[0051] In the described embodiment, the suction inlet comprises a plurality of openings aligned in a grid pattern along this side of the suction housing 120, the openings being defined by a transverse member and an expansion conduit 140. However, in alternative embodiments, it is conceivable that the suction inlet may, as desired, comprise a single opening (in some such embodiments, the entire lower side of the suction housing 120 may be open), or any other suitable number of openings.

[0052] The expansion module 130 may be coupled to the suction housing 120. In a preferred embodiment, as will be described in more detail below, the expansion module 130 may be slidably coupled to the suction housing 120. The expansion module 130 includes an inflator, which may include, for example, a disc inflator. However, other embodiments can be conceived in which the inflator may instead comprise another type of inflator, such as a tubular inflator or another preferred inflator.

[0053] The suction housing 120 may have a first side or lower side having a suction inlet, which may be configured to allow ambient air to be drawn into the airbag cushion 124 during inflation, as described above. The suction housing 120 may further have a second side or upper side opposite to the first side, which may be configured to receive the airbag cushion 124 and / or the airbag cushion package 110 inside. A third side of the suction housing 120 may extend between the upper / upper end and the lower / lower end and may be closed or at least substantially closed.

[0054] This opening, or in other embodiments, one or more openings, may be configured to be closed, or at least substantially closed, by the expansion module 130. More specifically, the expansion module 130 may be configured to be received on the opening side of the suction housing 120 and to close the opening / opening when fully coupled with the expansion module 130 (meaning fully sliding into the module in the described embodiment).

[0055] The inflation module 130 further comprises a plurality of inflation conduits 140, such as tubes, which are fluid-coupled to the inflator. Each of the inflation conduits 140 is provided with a plurality of inflation or suction ports 142 (alternatively referred to as suction ports, as they assist in drawing ambient air into the cushion 124 during inflation), and each of the inflation conduits 140 and / or ports 142 is configured to deliver inflation gas from the inflator into the airbag cushion 124. Preferably, the assembly 100 is configured to deliver the inflation gas at a sufficiently high speed so as to draw ambient air into the airbag cushion 124 through the suction inlets during inflation. In alternative embodiments, each of the ports 142 may be formed into a nozzle or the like that may extend from one or more of the inflation conduits 140.

[0056] In the embodiment depicted in Figure 1, the expansion / suction ports 142 are formed within each expansion conduit 140 in two opposing rows. Thus, ports 142a are part of the first row, and ports 142b are part of the second row. Preferably, these two rows are offset from each other with respect to the center of each expansion conduit 140. In other words, if the center is measured perpendicular to the long axis of each expansion conduit 140, each of the ports 142a in one row is offset from the center preferably toward the first side of the expansion conduit 140 adjacent to the first suction opening of the suction inlet, and each of the suction ports 142b in the second row of suction ports is offset from the center toward the second side of the same expansion conduit 140, opposite the first side, and preferably adjacent to another second suction opening of the suction inlet. In some embodiments, as discussed below and depicted in the embodiment of Figure 4, the ports may also, or alternatively, be formed in rows that are staggered and / or offset from each other, rather than at the center of each conduit.

[0057] In this way, the jet / expansion delivered through port 142 can be positioned closer to the opposing edge of conduit 140, which may enable a more efficient suction system by generating a better suction flow. While not limited to theory, this is thought to preferably be by positioning the ultrasonic plume of gas closer to the edge of the tube / conduit 140, thereby positioning the low-pressure zone generated by such high-velocity gas closer to where ambient air is drawn in or where air is drawn into the cushion more efficiently in a larger volume. This also improves the vacuum pressure for drawing more ambient air into the cushion compared to the amount of expanding gas required to generate the flow, thereby potentially increasing the suction rate of the assembly.

[0058] Furthermore, it may be preferable that the ports 142 be sufficiently spaced apart from each other so that the streamlines of the expanding gas do not intersect, or at least the intersection is minimized. Therefore, preferably, the ports 142 are spaced apart with the maximum amount of space between each adjacent port in the area allocated to the suction inlet, as in the embodiment described.

[0059] As shown in Figure 2, the assembly 100 may further comprise a valve assembly 160. The valve assembly 160 may comprise one or more valves, preferably configured to open automatically when the inflator is operating, and further configured to close automatically during inflation of the airbag cushion, in order to prevent air and expansion gas from escaping through the suction inlet below the valve flap of the valve assembly 160. In some embodiments, one or more valves of the valve assembly 160 may be configured to close automatically at a predetermined stage during inflation of the airbag cushion.

[0060] In the depicted embodiment, the valve assembly 160 comprises a first valve 162a or valve flap and a second valve 162b or valve flap. The valves 162a and 162b may include flaps, such as butterfly flaps, configured to automatically open and close at least two separate openings of the suction inlet. In some embodiments, including the depicted embodiment, these flaps may be configured to open and close each of the openings defining the suction inlet. In the depicted embodiment, each of the valves 162a and 162b comprises two flaps pivotably coupled to each other at a central portion, such as a hinge portion 161 of the respective valve. Thus, as shown in Figure 2, the valves 162a and 162b may be configured to pivot to their respective open configurations during inflation by pivoting their respective flaps at this central portion / centerline 161.

[0061] In some embodiments, the valve flaps of the valve assembly 160 may be sufficiently flexible so that the flaps flex during inflation. However, in some embodiments, these flaps may be sufficiently rigid to maintain a bias toward their respective closed configurations. In other words, the valve and / or valve flaps may be configured to require an opening force (generated by a partial vacuum within the associated airbag cushion) and, otherwise, to be biased toward their respective closed configurations. In some embodiments, the valve flaps themselves may be configured to perform this function independently, while in other embodiments, support members for such valve flaps, such as hinges, may be provided to facilitate the desired opening and closing function.

[0062] In some embodiments, the valve flap may comprise a relatively rigid material (at least compared to the fabric of the airbag cushion 124). In some embodiments, such a valve flap may be configured to operate in a desired manner simply by rigidly coupling such a flap adjacent to the suction inlet. Alternatively, the flaps 162a / 162b may be hinged at one end so that they are biased toward their respective closed positions. Some embodiments may comprise flaps that partially or completely overlap each other.

[0063] The valve assembly 160 may also be slidably coupled to the suction housing 120. Thus, as shown in Figure 2 (showing flaps 162a / 162b in the open configuration), for example, the pivot point of the flaps 162a / 162b of the valve assembly 160 may comprise an elongated projection or bead 161, which may be slidably received in a corresponding elongated slot formed along the lower portion of the suction housing 120. Both the projection / bead 161 and their corresponding slots preferably comprise a bulbous lower portion and a narrowed neck portion to ensure that the valve assembly 160 is held in its proper position within the suction housing 120.

[0064] Furthermore, the cross-sectional view in Figure 2 depicts the flaps / valves 162a and 162b of the valve assembly 160 in an open configuration during inflation of the airbag cushion 124. As previously mentioned, directing the high-speed inflation gas through the inflation port 142 creates a pressure difference, which preferably causes the valves and / or flaps of the valve assembly 160 to open automatically (i.e., without further mechanical elements or other forces / actions). This allows the inflation of the airbag cushion 124 to be supplemented by ambient air, which can enter the airbag cushion 124 through one or more openings of the suction inlet. Preferably, the inflation port 142 may be used to generate a sufficient pressure difference to allow the valve flaps 162a / 162b to open automatically. This same pressure difference may then allow ambient air to assist in the inflation of the airbag cushion 124. Preferably, the inflation gas is introduced into the airbag cushion 124 in a forced manner. Therefore, in addition to and / or instead of the pressure difference, the rate and / or percentage of the amount of gas delivered through port 142 may be sufficient to enclose ambient air in the expanding gas and, therefore, draw it into the airbag cushion 124 together with this expanding gas.

[0065] At a desired point during inflation, the valves and / or flaps 162a / 162b of the valve assembly 160 automatically close to prevent air and inflation gas from leaking out, or at least reduce the amount of air and inflation gas that may leak from the airbag cushion 124. Again, this can be achieved in numerous ways, but preferably the valves and / or flaps of the valve assembly 160 are biased toward their respective closed positions, either by hinges, by the physical structure of the hinges and the coupling / pivot points of the mounting, or otherwise, such that a threshold amount of force and / or pressure is required to reposition them to their open configuration and then automatically return them to their closed configuration.

[0066] Therefore, the valve / flap of the valve assembly 160 is preferably configured to operate initially in a closed configuration and then automatically open during inflation, which can be achieved, for example, by creating a partial vacuum within the airbag cushion 124 due to the inflation gas from the inflator. Following inflation, the system may be configured to automatically close again to maintain gas (both ambient air and inflation gas) within the cushion during occupant contact. The system may be specifically configured, by positioning and configuring valves, conduits, ports, etc., to automatically provide these three stages (closing, opening during inflation, and closing again during or after inflation) at desired times.

[0067] More specifically, during the initial deployment, before the cushion 124 breaks through the cover (the "breakthrough phase" of deployment), considerable pressure can be achieved within the cushion 124. This high pressure makes leakage from the rear of the housing highly likely unless the suction inlet is blocked. The inability to block the suction inlet can also prevent the desired cushion restraint. Following the breakthrough phase, it is preferable to open the suction inlet as quickly as possible to allow ambient air to assist the expansion process.

[0068] Here again, the valve flaps 162a / 162b may be configured to automatically re-close following the aforementioned decrease in pressure difference, the development of a pressure difference in the opposite direction, and / or the cessation of the expansion gas being delivered through the expansion port 142. As previously mentioned, in some embodiments, the valve flaps 162a / 162b may be biased toward their respective closed positions to facilitate this expansion stage. One or more airbag cushion vents (not shown) may be used and may be adjusted to provide desired deployment / restraint characteristics.

[0069] In the described embodiments, as shown in Figures 2 and 3, the suction housing 120 comprises a pair of elongated channels 123 configured to receive a corresponding pair of elongated rails 113 formed in the airbag cushion package 110. This allows, in some embodiments, the airbag cushion package 110, the suction housing 120, and the inflation module 130 to be slidably coupled to one another without the use of any fasteners, or at least substantially without the use of fasteners.

[0070] As shown in these figures, the expansion module 130 further comprises a frame defined by a plurality of support members extending perpendicularly to the expansion conduit 140. Additional support members may extend parallel to the conduit 140. Such parallel support members 148 may define the boundaries of the conduit 140 on both sides of the frame. As shown in Figure 3, a pair of elongated grooves 125 may be formed within the suction housing 120. In some embodiments, the support members 148 may include projections 149 that can be received within the grooves 125.

[0071] Figure 3 also depicts a preferred configuration of the expansion / suction port 142. Specifically, ports 142a and 142b are preferably formed by multiple components that give rise to a flared distal portion. In some more preferred embodiments, the flared distal portion comprises an angled surface that forms a flared angle feature, which may further comprise a Prandtl-Meyer feature. In other words, in some embodiments, each of the ports 142a in the first row is initially angled outward toward the first side of its expansion conduit 140, and each of the ports 142b in the second row is angled outward in the opposite direction toward the second opposite side of the expansion conduit 140.

[0072] distal to this portion (from the viewpoint of the expanding gas), one or more surfaces 143 defining the spreading angle are formed, and these surfaces can open / enlarge the port 142 and / or preferably be angled in the opposite direction to the adjacent proximal portion of the port 142. In some embodiments, including the embodiments depicted in Figures 2 and 3, each angled surface 143 may be angled in a direction perpendicular to (perpendicular to upward in Figures 2 and 3) at least substantially corresponding to the direction of arrival of ambient air through the suction inlet during deployment. In preferred embodiments, including the embodiments depicted, the angled surfaces 143 may further extend in a direction at least substantially perpendicular to a plane extending through each longitudinal axis of each of the plurality of expansion conduits 140.

[0073] In a more preferred embodiment, ports 142a and 142b may be angled with respect to the vertical at their respective proximal portions from about 0 to about 45 degrees (angle α in Figure 3). In some such embodiments, angle α may be from about 10 to about 30 degrees. In some such embodiments, angle α may be about 25 degrees.

[0074] Similarly, in a preferred embodiment, the angled surface 143 defines an angle of about 5 to about 35 degrees with respect to each adjacent proximal portion of its respective suction port (angle β in Figure 3). In some such embodiments, angle β may be about 25 degrees. Thus, in the embodiments described, angles α and β may be the same, or at least substantially the same, but this is not required for all conceivable embodiments.

[0075] Here again, though not limited to theory, this preferred geometry may allow the plume to flow more parallel to the suction air flowing into the cushion 124 of assembly 100 by changing the plume from a proximal angled portion (about 25 degrees from vertical in a preferred embodiment) to vertical or nearly vertical. Additionally, the use of Prandtl-Meyer angled surfaces may be useful in creating an expanding fan, in practice increasing the gas velocity along the outer surface of the plume opposite the angled surface. Tuning the plume with increasing outermost surface gas velocity may facilitate more efficient suction, for example, by allowing a larger suction mass flow compared to the inflator gas mass flow required to generate suction.

[0076] Figure 4 depicts a suction airbag cushion assembly 200 according to an alternative embodiment. The suction airbag cushion assembly 200 comprises an airbag cushion package and / or housing (the housing and cushion may be similar to those shown in Figure 2, but not shown in Figure 4) having an airbag cushion positioned and configured to deploy therefrom. The suction airbag cushion assembly 200 further comprises a suction housing 220 coupled to the airbag cushion housing. The suction housing 220 may be similar to the suction housing 120 and therefore may have, for example, a suction inlet configured to allow ambient air to be received into the airbag cushion during inflation.

[0077] Similarly, the inflation module 230 may be coupled to the suction housing 220. The inflation module 230 may further comprise a plurality of inflation conduits / tubes 240 fluidly coupled to the inflator, as in the inflation module 130. Here again, each of the inflation tubes 240 comprises a plurality of inflation or suction ports 242, and each of the inflation tubes 240 and / or ports 242 is configured to deliver inflation gas from the inflator into the airbag cushion.

[0078] The expansion / suction ports 242 are formed within each expansion conduit 240 in two opposing rows, similar to ports 142. Thus, ports 242a are part of the first row, and ports 242b are part of the second row. Similarly, as with ports 142, these two rows are offset from each other with respect to the center of each expansion conduit 240. In other words, if the center is measured perpendicular to the long axis of each expansion conduit 240, each of the ports 242a in one row is offset from the center toward the first side of the expansion conduit 240, preferably adjacent to the first suction opening of the suction inlet, and each of the suction ports 242b in the second row of suction ports is offset from the center toward the second side of the same expansion conduit 240, opposite to the first side, and preferably adjacent to another second suction opening of the suction inlet.

[0079] However, unlike port 142, the ports 242a of the first row are staggered or offset from the ports 242b of the second row such that each of the ports 242a of the first row is positioned along the long axis of the expansion conduit 240, where both rows are adjacent to the ports 242b of the second row. This staggered feature of the assembly 200 may have several advantages. For example, having staggered-arranged ports may improve the unfolding load strength by providing increased strength to the assembly. This may also increase the strength of the part by increasing the area between the nearest ports of opposing rows.

[0080] Other features and / or remainder of the port of assembly 200 may be identical or similar to any of those described above. For example, in some embodiments, the port 242 may be angled away from the vertical at least initially. In some such embodiments, the port may be multifaceted, multisectioned, and / or spread in the region from proximal to distal. For example, angled surfaces such as Prandtl-Meyer spreading faces may direct the expanding gas perpendicular or nearly perpendicular from the initial outward direction to improve the suction efficiency of adjacent ambient air during deployment.

[0081] A portion of another suction airbag cushion assembly 300 is shown in Figures 5A–5C. Similar to the previous embodiment, the suction airbag cushion assembly 300 comprises a suction housing 320, from which an airbag cushion (not shown in Figures 5A–5C, see Figure 2 as an example) is positioned and configured to deploy therefrom. In some embodiments, the suction housing 320 has an opening on its upper side and / or opening which may be configured to connect with the airbag cushion housing of assembly 300.

[0082] Although not shown in Figures 5A–5C so as to highlight the aspects of the inflator module of assembly 300, it should be understood that on the opposite side of the aforementioned opening, the suction housing 320 may have a suction inlet configured to allow ambient air to be drawn into the airbag cushion during inflation. As previously mentioned, in some embodiments, this suction inlet may comprise a plurality of openings aligned in a grid pattern along this opening side of the suction housing 320. However, in alternative embodiments, it is conceivable that the suction inlet may, as desired, comprise a single opening (in some such embodiments, the entire lower side of the suction housing 320 may open) or any other preferred number of openings.

[0083] The inflator module 330 may be coupled to the suction housing 320. In the described embodiment, the end cap 336 may extend from and / or be coupled to the suction housing 320. The end cap 336 comprises a plate portion 339 and an inflator hub portion 338 extending from the plate portion 339.

[0084] In the described embodiment, the end cap 336 is connectable to the housing 320. However, it should be understood that various alternative embodiments are conceivable. For example, any of the aforementioned components that are integrally connected to each other in the described embodiment, such as the inflator hub 338 and the plate 339, may instead be connectable to each other. Similarly, any of the aforementioned components that are separate and connectable to each other, such as the suction housing 320 and the end cap 336, may instead be integrally connected to each other, if desired.

[0085] The inflator module 330 is configured to be coupled to an inflator hub 338. More specifically, in the embodiment described, the inflator module 330 comprises an inflator 332 configured to be received within a cylindrical opening defined by the inflator hub 338. The inflator module 330 further comprises an inflator flange 334, which is formed as a cylindrical ring or plate, extending around the proximal portion of the inflator 332 and configured to be coupled to the inflator hub 338, as shown in Figure 5B.

[0086] As shown in Figure 6A, in some embodiments, the inflator hub 338 may have grooves 337 extending around its proximal portion (relative to the inflator module 330). These grooves 337 provide a place for crimping the inflator flange 334, as will be described later, and can facilitate the crimping of the inflator flange 334 to the inflator hub 338.

[0087] After the inflator module 330 is coupled to the inflator hub 338 by inserting the inflator 332 into the inflator hub 338 and extending the inflator flange 334 around the proximal portion of the inflator hub 338, a crimp 335 may be formed around the entire circumference, preferably the inflator flange 334 and the inflator hub 338, or at least substantially around the entire circumference, as shown in Figure 5C. Here again, in preferred embodiments and configurations, this crimp may be carried out to crimp the preferably metal inflator flange 334 into an annular groove 337.

[0088] This crimping procedure can be carried out using any method and / or tools currently available to those skilled in the art, or which may be developed later and made available to those skilled in the art. For example, in some implementations, a circular and / or cylindrical crimping tool having crimping jaws with multiple radial segments may be used. In a preferred implementation, this configuration and crimping procedure may allow an inflator, such as inflator 332, to be fixedly coupled to an inflator hub, such as a cylindrical inflator hub 338, without the use of any screws, bolts, pins, rivets, or other fasteners. In some such embodiments, the inflator may be fixedly coupled to the inflator hub of a suction airbag assembly, or in some cases another airbag assembly, without any pre-formed and / or releaseable fastening elements, such as clips, prongs, etc.

[0089] Figures 6A and 6B are cross-sectional views of the inflator side of assembly 300 during the process of crimping / coupling the inflator 332 to the inflator hub 338 (via the inflator flange 334). As shown in Figure 6A, the inflator module 330 can first be temporarily coupled to the inflator hub 338 by inserting the inflator 332 into the cylindrical opening formed by the inflator hub 338, with the inflator flange 334 extending over the outer surface of the proximal portion of the inflator hub 338.

[0090] Next, as depicted in Figure 6B, the inflator flange 334 can be crimped or otherwise deformed to fixate the inflator 332, to which the inflator flange 334 extends and / or to the airbag assembly 300 (more specifically, to the inflator hub 338 portion of the end cap 336).

[0091] As described above in relation to various other embodiments, the inflator 332 may then be fluidly coupled to one or more expansion conduits 340, such as tubes. Each of these expansion conduits 340 preferably comprises a plurality of expansion or suction ports (not shown) configured to deliver expansion gas from the inflator 332 into the airbag cushion. Preferably, the expansion gas is delivered at a sufficiently high velocity to draw ambient air into the airbag cushion through the suction port during expansion. In some embodiments, each of the ports may be formed as a nozzle, etc., which may extend from one or more of the expansion conduits 340.

[0092] Figures 7A–7C depict portions of another alternative embodiment of the suction airbag assembly 400. As with the previous embodiment, this embodiment is depicted from the inflator side of the assembly 400. Therefore, it should be understood that the remaining features and / or elements of the assembly 400 may, but do not have to be, identical or similar to those described elsewhere in this specification in relation to other embodiments. Here again, these elements are not shown in order to focus on a distinct aspect of this assembly 400 compared to the previous embodiment.

[0093] Similar to assembly 300, assembly 400 includes an inflator module 430 which can be coupled to a suction housing 420. An end cap 436 may be coupled to the suction housing 420, which here again may include a plate portion 439 and an inflator hub portion 438 extending from the plate portion 439. The inflator module 430 here again is configured to be coupled to the inflator hub 438. However, in this embodiment, a crimping-promoting element 470 is provided to facilitate a stronger and / or more secure coupling of the inflator 430, which may be useful considering the relatively high inflator thrust loads that may be expected during operation.

[0094] In the described embodiment, the crimping facilitator element 470 includes a tubular element or a ring. The ring 470 may optionally have a plurality of holes 474. As described below, the holes 474 may further enhance the strength / stability of the bond by allowing a material such as a thermoplastic material that can be deformed during or in connection with the crimping process to enter one or more of the holes 474, thereby further locking the inflator module 430 to the inflator hub 438.

[0095] In the described embodiment, the ring 470 may be slid over the inflator hub 438 and then overmolded onto the inflator hub 438. Thus, the hole 474 may function as a location that can provide additional stability to the bond / fixation between the ring 470 and the inflator hub 438 by allowing the deformed thermoplastic material to flow into the hole 474 during the overmolding process. This overmolded portion is shown as 437 in Figures 7B and 7C.

[0096] In alternative embodiments, a cylindrical slot may be formed in the inflator hub 438. In some such embodiments, a narrowed collar portion may be formed along the inflator hub 438, which may form the inner surface of the aforementioned slot. In some such embodiments and implementations, the ring 470 may be inserted into the slot before the inflator 432 is coupled to the inflator hub 438.

[0097] As shown in Figure 7C along with the cross-sectional view in Figure 8B, the inflator flange 434 may then be crimped onto the proximal end of the ring 470, which may include a protruding collar 472 to facilitate this crimping process. In some embodiments and configurations, the collar 472 may be provided instead of a crimping groove such as a groove 337. However, some embodiments and configurations may include both a crimping groove and a ring with a collar, if desired.

[0098] As previously mentioned, in some embodiments, the crimping and / or other steps of the assembly process may involve redistribution, such as melting, of material into and / or through holes 474 formed in the ring 470. Thus, in some embodiments, at least a portion of the inflator hub 438 may include thermoplastic material, which may be melted or otherwise redistributed either before, during, or after the crimping process to facilitate a stronger and / or more stable bond.

[0099] Various alternative embodiments and implementations can be conceived. For example, although the holes 474 are depicted in Figure 7A as being arranged in a staggered pattern along the distal portion of the ring 470, it should be understood that this is merely one embodiment of possible arrangements of holes / openings to facilitate a more stable coupling of the inflator to the inflator hub of the suction or other airbag assembly. As an alternative configuration, the holes 474 may be located elsewhere, such as along the proximal portion of the ring 470, or in some cases across the entire ring 470.

[0100] Here again, in preferred embodiments and implementations, the inflator 432 may then be fluid-coupled to one or more expansion conduits 440. Although not shown in the partial diagrams of Figures 8A and 8B, each of these expansion conduits 440 preferably comprises a plurality of expansion or suction ports configured to deliver expansion gas from the inflator 432 into the airbag cushion. Preferably, the expansion gas is delivered at a sufficiently high velocity to draw ambient air into the airbag cushion through the suction inlet of the assembly during expansion. In some embodiments, each of the ports may be formed as a nozzle, such as a high-speed nozzle, each of which may be fluid-coupled to one or more of the expansion conduits 440.

[0101] The above specification has been described with reference to various embodiments and implementations. However, those skilled in the art will understand that various modifications and changes can be made without departing from the scope of this disclosure. For example, various operational steps, and the components for performing the operational steps, can be implemented in various ways depending on the particular application or taking into account any number of cost functions associated with the operation of the system. Thus, any one or more of the steps can be deleted, modified, or combined with other steps. Furthermore, this disclosure should be considered illustrative rather than restrictive, and all such modifications are intended to be within the scope of this disclosure. Similarly, with respect to various embodiments, benefits, other advantages, and solutions to problems have been described above. However, benefits, advantages, solutions to problems, and any elements that may produce or make more prominent any benefits, advantages, or solutions should not be construed as important, necessary, or essential features or elements.

[0102] Those skilled in the art will understand that many modifications can be made to the details of the embodiments described above without departing from the basic principles of the present invention. Therefore, the scope of the present invention should be determined solely by the following claims.

Claims

1. A method for assembling a suction airbag cushion assembly [300, 400], comprising inserting at least a portion of an inflator module [330, 430] into an inflator hub [338, 438] of the suction airbag cushion assembly [300, 400], wherein the inflator module [330, 430] A method comprising an inflator [332, 432] and an inflator flange [334, 434], wherein the method includes pressing the inflator flange [334, 434] onto the inflator hub [338, 438].

2. The method according to claim 1, wherein the inflator flange [334, 434] comprises a cylindrical plate [334, 434] coupled to the inflator [332, 432].

3. The inflator hub [338] is provided with a cylindrical recess [337], and the step of inserting at least a portion of the inflator module [330] into the inflator hub [338] is: The inflator [332] extends into the cylindrical recess [337], The method according to claim 2, further comprising extending the inflator flange [334] around the outer surface of the inflator hub [338].

4. The method according to claim 3, wherein the step of pressing the inflator flange [334] onto the inflator hub [338] includes pressing the cylindrical plate [334] onto the outer surface of the inflator hub [338] around the entire circumference of the cylindrical plate [334].

5. The method according to claim 1, wherein the step of pressing the inflator flanges [334, 434] onto the inflator hubs [338, 438] includes fixing the inflator modules [330, 430] to the inflator hubs [338, 438] without using any fasteners.

6. The method according to claim 1, further comprising coupling a crimping facilitating element [470] to the inflator hub [438], wherein the step of crimping the inflator flange [434] onto the inflator hub [438] includes crimping the inflator flange [434] onto a portion of the crimping facilitating element [470].

7. The method according to claim 6, wherein the crimping promoting element [470] includes a ring [470].

8. The method according to claim 7, wherein the ring [470] includes a metal ring [470] and the inflator flange [434] includes a metal inflator flange [434].

9. The method according to claim 7, wherein the ring [470] comprises a plurality of holes [474], and further comprises the step of overmolding plastic material into at least a subset of the plurality of holes [474] in order to fixatively connect the ring [470] to the inflator hub [438].

10. The method according to claim 1, further comprising connecting a metal ring [470] to the inflator hub [438].

11. The method according to claim 10, wherein the step of connecting the metal ring [470] to the inflator hub [438] includes inserting the metal ring [470] onto the outer surface of the inflator hub [438].

12. The method according to claim 11, wherein the step of connecting the metal ring [470] to the inflator hub [438] further comprises overmolding the metal ring [470] onto the inflator hub [438].

13. The method according to claim 12, wherein the metal ring [470] comprises a plurality of holes [474], and the step of overmolding the metal ring [470] onto the inflator hub [438] includes melting a thermoplastic material in at least a subset of the plurality of holes [474].

14. The method according to claim 11, wherein the metal ring [470] comprises a protruding collar [472].

15. The method according to claim 14, wherein the step of pressing the inflator flange [434] onto the inflator hub [438] includes deforming the inflator flange [434] with respect to the protruding collar [472] of the metal ring [470].

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