Biased bag wrap for rimless steering wheels

Abstract

An apparatus for assisting in protecting a driver's side occupant of a vehicle having a steering yoke includes an airbag mounted to the steering yoke. The airbag is inflatable from a stored state concealed within the steering yoke to a deployed state in which the airbag is positioned between the steering yoke and the occupant. The apparatus also includes an airbag wrap for packaging the airbag in the stored state. The airbag wrap is configured to bias the airbag to initially deploy in an initial deployment direction transverse to a steering axis of the steering yoke through a deployment opening defined by the airbag wrap and pleats formed in the airbag wrap and secured with tear stitches. The pleats are configured to initially reduce the size of the deployment opening, thereby limiting initial deployment of the airbag through the deployment opening. The pleats are further configured to break in response to an increase in airbag deployment force to increase the size of the airbag for further deployment through the deployment opening.

Description

[Technical Field]

[0001] This disclosure relates to devices for assisting in the protection of vehicle occupants in the event of an event such as a vehicle collision. In particular, the present invention relates to a driver airbag module configured to be mounted to the steering wheel of a vehicle. [Background technology]

[0002]

[0002] The automotive industry is moving toward vehicles with autonomous driving capabilities, with purely autonomous or "driverless" vehicles on the horizon. Driver control is evolving along with this trend. As automated control increasingly takes over driving functions, the need for traditional driver control is changing and / or reducing.

[0003] One area where driver control is evolving is the steering wheel. As automated driving functions become more prevalent, the use of steering wheels may be reduced, but vehicles still need to include a steering wheel. As a result, steering wheels are sometimes designed to have a reduced presence within the vehicle cabin. One example of such a design is a steering wheel with a partial rim design, where the upper and sometimes lower portions of the steering wheel rim are removed. This configuration is sometimes referred to as a steering yoke configuration.

[0004] However, conventional steering wheel-mounted driver frontal airbags may utilize a conventional round, full-rim configuration for several reasons. For example, a conventional frontal airbag may have an overall rounded, pillow-shaped configuration and utilize the steering wheel rim as a reaction surface for the airbag upon deployment. Because yoke steering wheels omit the upper portion of a conventional steering wheel rim, the driver frontal airbag configuration may need to be designed to account for this omission.

[0005] Additionally, an out-of-position (OOP) occupant may tilt their head forward relative to the steering wheel. In a conventional round, full-rim steering wheel configuration, the occupant's head engages the upper portion of the steering wheel rim, which prevents the head from moving further forward (into the vehicle). A yoke steering wheel omits the upper rim portion of the steering wheel, thus allowing an OOP occupant to move further forward in the vehicle. Summary of the Invention [Means for solving the problem]

[0006] The driver airbag module is configured to be mounted on a steering wheel that omits the upper portion of a conventional circular steering wheel rim. A non-limiting example of such a steering wheel configuration is what may be referred to as a yoke steering wheel. The driver airbag module may be mounted on any steering wheel that does not have a conventional upper steering wheel rim portion or has an equivalent configuration.

[0007] According to one aspect, an apparatus for assisting in the protection of a driver's side occupant of a vehicle having a steering wheel includes an airbag mounted to the steering wheel. The airbag is inflatable from a stored state concealed within the steering wheel to a deployed state in which the airbag is positioned between the steering wheel and the occupant. The apparatus also includes an airbag wrap for packaging the airbag in the stored state. The airbag wrap is configured to bias the airbag to initially deploy in an initial deployment direction transverse to a steering axis of the steering wheel through a deployment opening defined by the airbag wrap and pleats formed in the airbag wrap and secured with tear stitches. The pleats are configured to initially reduce the size of the deployment opening, thereby limiting the initial deployment of the airbag through the deployment opening. The pleats are further configured to rupture in response to an increase in airbag deployment force to increase the size of the airbag for further deployment through the deployment opening.

[0008]

[0008] According to another aspect, the airbag wrap may be further configured to limit movement of the airbag in directions other than the initial deployment direction so that the airbag wrap urges the airbag to deploy in the initial deployment direction through the deployment opening.

[0009] According to another aspect, the airbag wrap can be configured such that the deployment opening is at least partially defined by an edge of the wrap configured to disperse at least a portion of the initial airbag deployment force away from the edge of the cover behind which the airbag and airbag wrap are stored. The edge of the wrap can include a scalloped edge. The scalloped edge can include an edge that curves inward toward a central portion of the cover.

[0010] According to another aspect, the airbag and airbag wrap may be components of an airbag module. The airbag module may further include an inflator for inflating the airbag and a retainer to which the inflator, airbag, and airbag wrap are secured. The retainer may be configured to connect to the steering wheel to mount the airbag module to the steering wheel. The airbag module may be a component of a vehicle safety system.

[0011] According to another aspect, the airbag wrap may include a central portion configured to cover the airbag. The airbag wrap may also include a first wrap portion extending from the central portion in a first direction, wrapping around the airbag, the inflator, and the retainer, and secured to a rear portion of the retainer. The airbag wrap may also include a second wrap portion extending from the central portion in a second direction opposite the first direction, wrapping around the airbag, the inflator, and the retainer, and secured to a rear portion of the retainer. The airbag wrap may further include a third wrap portion extending from the central portion in a third direction transverse to the first and second directions, wrapping around the airbag, the inflator, and the retainer, and secured to a rear portion of the retainer. The third direction may be opposite the initial deployment direction.

[0012] According to another aspect, the airbag wrap may be configured to package the airbag in a folded state and to define a deployment opening facing the initial deployment direction. The airbag wrap may be further configured to limit movement of the airbag in directions other than the initial deployment direction such that the airbag wrap biases the airbag to deploy through the deployment opening in the initial deployment direction.

[0013]

[0013] According to another aspect, the central portion and the first, second, and third wrap portions define deployment openings, and their respective connections to the back of the retainer can limit movement of the airbag in directions other than the initial deployment direction.

[0014] According to another aspect, the second lap portion can be folded to form a pleat, and a tear stitch can extend through the pleat to connect the folded portion of the second lap portion to the central portion.

[0015] According to another aspect, the device may also include a retainer and fastener studs extending through fastener-receiving openings at the ends of the first, second, and third wrap portions for securing the first, second, and third wrap portions to the retainer. The fastener studs may also secure the airbag and inflator to the retainer.

[0016] According to another aspect, the airbag may have a generally circular pillow-shaped configuration, and the normal deployment position of the airbag may be generally centered about the steering axis.

[0017] According to another aspect, the steering wheel may have a steering yoke configuration.

[0018]

[0018] According to another aspect, the initial deployment direction may be configured to be transverse to the vehicle.

[0019]

[0019] According to another aspect, the initial deployment direction may be configured to be a direction laterally inward relative to the vehicle.

[0020]

[0020] According to another aspect, the initial deployment direction can be configured to be to the side of an area above the steering wheel where an out-of-position occupant's head can rest.

[0021]

[0021] According to another aspect, the airbag may be configured such that deployment in an initial deployment direction directs the airbag's deployment energy away from the area above the steering wheel where an out-of-position occupant's head may rest.

[0022]

[0022] According to another aspect, the airbag may be configured such that deployment in an initial deployment direction applies an initial low deployment energy to the OOP occupant's head, causing an initial low energy movement of the OOP occupant's head away from the steering wheel.

[0023]

[0023] According to another aspect, the airbag may be configured to further move the OOP occupant's head away from the steering wheel after the initial deployment energy has been dissipated by the airbag moving back toward the steering axis to a normally deployed state.

[0024]

[0024] The above-mentioned and other features will become apparent to those skilled in the art to which this disclosure pertains upon review of the following description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a schematic diagram of a vehicle including an apparatus for assisting in the protection of vehicle occupants, according to an exemplary arrangement. [Figure 2]

[0026] FIG. 2 is a schematic plan view of a steering wheel mounted on the vehicle of FIG. 1. [Figure 3]

[0027] FIG. 2 is a schematic diagram showing components of the airbag module portion of the device. [Figure 4]

[0028] FIG. 2 is a top view of the assembled airbag module. [Figure 5]

[0029] FIG. 2 is a side view of the assembled airbag module. [Figure 6]

[0030] 6A and 6B are schematic front views showing the inflation and deployment of an airbag of an airbag module. [Figure 7]

[0031] 7A and 7B are schematic top and front views showing the inflation and deployment of an airbag in an airbag module. [Figure 8]

[0032] FIG. 10 is a schematic diagram illustrating a portion of an airbag module according to an alternative configuration. [Figure 9]

[0033] 9A and 9B are schematic diagrams illustrating a portion of an airbag module according to another alternative configuration; DETAILED DESCRIPTION OF THE INVENTION

[0026]

[0034] Safety System Overview 1 illustrates an exemplary configuration of an apparatus 10 for assisting in the protection of an occupant 14 of a vehicle 12. For purposes of this description, the occupant 14 is the operator or driver of the vehicle, and these terms may be used interchangeably. The apparatus 10 includes a driver front airbag module 20 configured to be mounted to a steering yoke 50 on the driver's side 16 of the vehicle 12. The vehicle 12 also includes a seat belt 18 that helps to restrain the occupant 14 within a vehicle seat 28.

[0027]

[0035] The airbag module 20 includes an airbag 22, an inflation fluid source 24, such as an inflator, and a structure 26, such as a housing, for supporting the airbag 22 and inflator 24 within the vehicle 12. The airbag has a stored state, generally indicated by dashed lines at 22′, in which the airbag is deflated, folded, and stored within the housing 26. The housing 26 may include a cover 64 (see FIG. 2) that helps hide the airbag 22 within the steering yoke 50 while in the stored state.

[0028]

[0036] The inflator 24 is operable to inflate the airbag from a stored condition to a deployed condition generally indicated by the solid line at 22. Upon actuation of the inflator 24, the cover moves from a closed condition, which helps conceal the airbag 22 within the housing 26, to an open condition, which allows the airbag to inflate and deploy from the housing.

[0029]

[0037] The airbag 22 inflates and deploys away from the steering yoke 50 and generally parallel to the steering axis 36 of the vehicle 12. In the deployed state, the airbag 22 is positioned between the occupant 14 and the steering yoke 50, and between the occupant and the instrument panel 32 on the driver's side 16 of the vehicle 12. When in the deployed state, the airbag 22 helps absorb the force of a collision with the airbag and helps distribute the force of the collision across the airbag to provide occupant cushioning and a desired ride-down effect.

[0030] safety standards

[0038] The National Highway Traffic Safety Administration (NHTSA) is the U.S. government agency responsible for overseeing motor vehicle safety and evaluating the safety of new vehicles through its New Car Assessment Program (US-NCAP). Through US-NCAP, NHTSA develops crash tests to establish the crashworthiness of new vehicles and rates them with a five-star rating, out of which five is the highest. NHTSA also develops Federal Motor Vehicle Safety Standards (FMVSS), which NHTSA issues to ensure that vehicles sold in the United States meet various safety standards (pass / fail). FMVSS standards detail precise test procedures, which are determined from measurements taken with crash test dummies placed inside the vehicle during testing.

[0031]

[0039] The United States is not the only country with its own new car rating program. Other countries, such as China, Japan, and Australia, as well as other groups of countries in Europe and Latin America, have their own new car rating programs. The new car ratings issued by these agencies are similar, but some use crash tests in slightly different ways.

[0032]

[0040] One specific crash scenario for which NHTSA sets standards is called an out-of-position (OOP) occupant scenario. An OOP occupant scenario is one that involves an occupant being displaced from their normal seating position within the vehicle during a vehicle crash. In some OOP scenarios, an occupant may be positioned in close proximity to a safety device, such as an airbag. To help account for this possibility, NHTSA has established standards for testing vehicle and safety system performance in certain of these OOP scenarios, with the goal of maintaining occupant protection while considering the possibility of an OOP occupant.

[0033]

[0041] One specific OOP scenario for which NHTSA is setting standards is that of an OOP vehicle driver leaning forward with their head positioned against the rim of the steering yoke and their chin positioned against the steering yoke structure that is in contact with or adjacent to the airbag module 20. This may occur, for example, if the occupant falls asleep or if the driver leans forward to retrieve an item from the floor 30 or footwell 38 of the vehicle 12. In the event of a crash in this scenario, the occupant's head 40 may be positioned abnormally close to the airbag module 20 if the airbag 22 were to deploy.

[0034]

[0042] For this reason, NHTSA has included in its Federal Motor Vehicle Safety Standards a test to evaluate the performance of steering yoke-mounted airbag modules in an OOP scenario in which the occupant's head is positioned so that the occupant's chin 42 is above the airbag module 20 upon deployment. "Above the airbag module" means that the occupant's chin is positioned against, or as close as possible to, a specified location on the steering yoke structure relative to the airbag module 20 in accordance with specified test procedures.

[0035]

[0043] NHTSA's federal motor vehicle safety standards are codified in Title 49 Code of Federal Regulations Section 571.208, commonly referred to as FMVSS 208, the text of which is publicly available and incorporated herein by reference in its entirety. FMVSS 208 S26 specifies the procedure for low-risk deployment testing of driver airbags. Test Procedure 26.2 specifies the test procedure for an out-of-band driver with their chin positioned on the airbag module, referred to herein as the chin-on-module test. This test is conducted using what is referred to as the 5% female crash test dummy, meaning that the dummy is modeled after a statistical woman with a height and weight equal to or greater than the female population, but who represents only 5% of the female population. This statistical person is sometimes referred to as the 5th percentile female or small female occupant.

[0036] Steering yoke configuration

[0044] FIG. 2 is a schematic diagram of a steering yoke 50. As shown in FIG. 2, the steering yoke 50 has a shape that deviates from the rounded / circular shape typical of conventional steering wheel configurations. For comparison purposes, FIG. 2 shows in dashed lines the rim R of a conventional steering wheel having this conventional rounded / circular configuration. As shown, the steering yoke 50 has an overall R UPPER and R LOWER The upper and lower parts of the conventional rim R, identified by

[0037]

[0045] Steering yoke 50 resembles the type of control devices commonly found in aviation. However, the configuration of steering yoke 50 shown in FIG. 2 is not intended to limit or exhaust the types of steering yokes in which device 10 may be implemented. Device 10 may be mounted on all or part of the rim of a conventional steering wheel, particularly the upper portion R UPPER The present invention may be implemented in a steering yoke having any configuration, omitting the above.

[0038]

[0046] Steering yoke 50 includes left and right rim portions 52, 54 and a hub portion 56 through which steering axis 36 extends. Cross members or spokes 60, 62, 64, and 66 connect left and right rim portions 52, 54 to hub portion 56. A vehicle operator 14 can grasp rim portions 52, 54 to steer vehicle 12. As shown in FIG. 2 , steering yoke 50 can include various operator control devices 72 and 74, such as switches, buttons, knobs, etc., for controlling vehicle systems, such as information and entertainment (“infotainment”) systems and communication systems, such as hands-free cell phone control systems.

[0039]

[0047] As shown in FIG. 2 , the airbag module 20 may be mounted to the steering yoke 50 and housed under a sheath or cover 70 that opens upon airbag deployment. The cover 64 may open, for example, via a tear seam that ruptures under the inflation and deployment forces of the airbag 22. When inflated, the airbag 22 may have a generally rounded configuration and be generally centered about the steering axis 36. The phrase “generally centered” is intended to explain that although the airbag module 20 and airbag 22 reside within the hub portion 56 and the steering axis 36 passes through the hub, the airbag / airbag module and / or the steering axis may not be precisely centered about that axis. In this case, the steering axis 36 and the centers of the airbag module 20 and / or airbag 22 themselves are at least closely aligned vertically when the steering yoke 50 is in the illustrated “steering straight forward” position. As a result, the air bag 22 is generally centered about the steering axis 36 when it is inflated, deployed and normally positioned.

[0040]

[0048] Because the steering yoke 50 has the steering yoke configuration described above, an OOP occupant leaning forward and abutting the steering yoke does not have their head movement restricted by engagement with the upper rim portion (see FIG. 2). For example, an OOP occupant may lean forward with their chin directly engaging the cover 64 of the airbag module 20. Advantageously, the airbag module 20 is configured to improve its performance in the module chin rest test of FMVSS 208 S26.2, despite the absence of an upper rim portion. A structure of the airbag module 20 that improves module chin rest performance is shown in FIG. 3.

[0041] Airbag module

[0049] 3, the airbag module 20 is shown generally in an unassembled state and includes four basic components: an airbag 22, an inflator 24, an airbag retainer 80, and an airbag wrap 100. The airbag module 20 may include additional components that are not critical to the performance of the module chinrest and have been omitted for purposes of clarity.

[0042]

[0050] Assembly of the airbag module 20 is indicated generally by arrows in Figure 3, which results in the module being in its assembled state in Figures 4 and 5. Essentially, the inflator 24 is assembled to the retainer 80 by passing the inflator housing 90 through the central retainer opening 82 so that the inflator rim portion 92 engages the retainer. Fastener studs 84 pass through aligned openings in the retainer 80 and the inflator 24.

[0043]

[0051] The airbag 22 is positioned so that the mouth portion (not shown) is positioned over the retainer 80 and inflator 24, and the fastener studs 84 pass through the fastener openings adjacent to the mouth portion. The airbag 22 is folded in a desired manner, such as the star-fold configuration shown. The airbag wrap 100 has an overall T-shaped configuration. The airbag wrap 100 is installed by positioning the central portion 102 of the wrap over the folded airbag 22. By "over" the folded airbag, we mean that the central portion 102 covers the surface of the folded airbag 22 that faces toward the occupant generally along the steering axis 36. In other words, the upper portion 102 is positioned between the airbag 22 and the occupant 14 when the airbag module 20 is installed in the steering yoke 50 and prior to airbag deployment. Next, a first or upper wrap or wrap portion 110, a second or lower wrap or wrap portion 120, and a third or side wrap or wrap portion 130 are wrapped around the folded airbag 22, retainer 80, and inflator 24.

[0044]

[0052] On the rear side of the retainer 80, beneath the airbag 22, inflator 24, and retainer assembly as seen in FIG. 5 , the inflator-engaging portion 112 of the upper wrap 110, the inflator-engaging portion 122 of the lower wrap 120, and the inflator-engaging portion 132 of the side wrap 130 are positioned or engage with the cylindrical portion of the inflator 24. Fastener openings 114, 124, 134 are positioned over corresponding pairs of fastener studs 84, thereby connecting the upper wrap 110, the lower wrap 120, and the side wraps 130 to the rear of the retainer. Fasteners (not shown), such as nuts, are threaded onto the studs 84 to complete assembly of the airbag module 20.

[0045]

[0053] The order in which these steps for assembling the airbag 22, inflator 24, and retainer 80 are performed may be varied. For example, the airbag 22 and / or airbag wrap 100 may be assembled onto the retainer before the inflator 24, with the inflator installed thereafter, so that the inflator rim 92 sandwiches the airbag and wrap material and helps secure the airbag. Alternatively, the airbag module 20 may include a clamping plate that fits over the fastener studs 84, with the airbag 22, inflator 24, and wrap 100 sandwiched between the retainer 80 and the clamping plate. Aside from the airbag wrap 100, the disclosed configuration and assembly of the airbag module components is not critical. It should be appreciated that these components and their respective configurations may deviate from those shown and described herein without adversely affecting the functionality of the airbag wrap 100 described herein.

[0046] Airbag Wrap

[0054] The assembled airbag module 20 is shown in Figures 4 and 5. From the driver's perspective looking toward the steering yoke 50 from a seated position, i.e., the perspective of Figure 2, the central portion 102 of the airbag wrap 100 covers / packages the driver-facing portion of the folded airbag 22. The side portions 110, 120, 130 extend from the central portion 102 around the module 20 to their corresponding connections with the fasteners 84. The three wrap portions 110, 120, 130 of the airbag wrap 100 thus cover / package the folded airbag 22 on three corresponding sides. The first / upper wrap 110 packages the upper portion of the airbag 22 in its folded state. The second / lower wrap 120 packages the lower portion of the airbag 22 in its folded state. The third / side wraps 130 package the side portions of the folded airbag 22. Again, the upper, lower, and side portions of the folded airbag 22 are identified with reference to their relative positions when installed in the steering yoke 50, from the driver's perspective in FIG. 2. In that case, the side portions of the folded airbag covered / packaged by the third / side wraps 130 are the outboard side portions of the airbag 22.

[0047]

[0055] In the assembled state of the airbag module 20, the folded airbag 22 is enclosed or packaged within a packaging space 104 of the airbag module 20. The packaging space 104 is bounded on three sides by portions 110, 120, 130 of the airbag wrap 100, a front side (facing the occupant / driver) by a central portion 102 of the airbag wrap, and a rear side opposite the front side by the inflator 24 and retainer 80. The airbag wrap 100 leaves a deployment opening 106 open.

[0048]

[0056] FIG. 5 illustrates the packaged configuration of the airbag module 20 from a side perspective indicated by the arrows generally labeled 5-5 in FIG. 4. This view is an inboard-to-outboard view of the steering yoke 50 and airbag module 20. From this perspective, the airbag 22 can be seen folded in a star-fold configuration and covered / packaged within the packaging space 104 of the module 20. In this view, the packaged airbag 22 can be seen not covered / packaged by the airbag wrap 100 on the inboard side. To protect against damage, for example, during installation of the airbag module 20, the airbag 22 can be covered with a protective layer, such as a fabric sheet, configured to offer little or no resistance to tearing and deployment upon airbag inflation.

[0049]

[0057] The airbag wrap 100 is configured to bias the deployment of the airbag 100 to provide improved performance in a crash test conducted in accordance with FMVSS 208 S26 Procedure 26.2 in which an out-of-plane driver places their chin on the airbag module. Referring to FIGS. 6A-6B , the airbag wrap 100 biases the airbag 22 to deploy in an initial deployment direction that is generally transverse to the steering axis 36. In the exemplary configuration shown in the figures, the generally transverse direction may be generally perpendicular to the steering axis 36. This direction may be, for example, generally along or parallel to the steering plane, which is the plane of rotation of the steering yoke 50, and toward one of the steering yoke rim portions 52, 54. To help improve airbag performance in this module chin-rest test, the airbag deployment bias applied by the airbag wrap 100 causes the airbag 22 to deploy inward through the deployment opening 106 and generally laterally outward from the package space 104 during the initial stages of inflation. This is generally indicated by arrow 58, which indicates lateral expansion in FIG. 6A.

[0050]

[0058] As inflation continues, the airbag 22 continues to deploy laterally inward from the airbag module 20 and out of the packaging space 104, directed by the biasing force applied by the airbag wrap 100. As a larger and larger portion of the airbag 22 moves out of the packaging space 104, the biasing force applied by the airbag wrap 100 decreases. When the airbag 22 reaches a certain point or stage of inflation outside the packaging space 104, the airbag wrap 100 loses its ability to bias its deployment because a significant portion of the airbag has moved out of the packaging space 104 through the deployment opening 106. As a result, no airbag structure remains in the packaging space 104 to support the airbag wrap 100.

[0051]

[0059] When the airbag 22 is positioned substantially outside the packaging space 104, the inflating airbag exerts a deployment force on the airbag wrap from outside the packaging space, causing the airbag wrap 100 to collapse. As the airbag continues to inflate and pressurize, and the airbag wrap 100 no longer pressurizes the airbag 22 and collapses, the unpressurized airbag is released to conform to a predetermined shape in response to the pressurization. As a result, the airbag 22 moves in a direction generally opposite the initial deployment direction to its fully inflated, deployed, and normally positioned state shown in FIG. 6B.

[0052]

[0060] Advantageously, the deployment path imparted to the airbag 22 by the airbag wrap 100 helps improve airbag performance in the FMVSS Module Chin-Resistance Test. This is illustrated in Figures 7A-7C, which are schematic top views depicting an occupant 14, steering yoke 50, and airbag module 20. As shown in Figure 7A, the occupant 14 is out of position (OOP) with his head 40 on the steering yoke 50 and his chin 42 on the module 20.

[0053]

[0061] As shown in Figure 7B, during initial deployment of the airbag 22, the airbag wrap 100 biases the airbag 22 to deploy laterally inward, as generally indicated by the arrow labeled A in Figure 7B. As shown in Figure 7B, this initial laterally inward deployment may cause the occupant's head 40 to move slightly away from the steering yoke 50, as generally indicated by the arrow labeled B in Figure 7B. However, this initial head movement is minimal compared to the amount of movement that would be imparted to the occupant's head if the airbag 22 were biased not laterally inward, as in a conventional steering yoke-mounted driver front airbag, but instead directly toward the occupant 14.

[0054]

[0062] Continued laterally inward inflation from the airbag module 20 prevents the transfer of deployment energy from the airbag 22 to the occupant 14, and particularly the occupant's head 40. As the airbag 22 inflates significantly and the airbag wrap 100 collapses, the airbag moves back toward its normal inflated and deployed state, as shown generally by the arrow labeled C in FIG. 7C. This airbag movement causes the occupant's head 40 to move away from the steering yoke 50, as shown generally by the arrow labeled D in FIG. 7C. The airbag 22 continues to inflate and pressurize, moving to its fully inflated, deployed, and normally positioned state shown in FIG. 7C, significantly reducing the amount of deployment energy transferred to the occupant's head 40 and thereby significantly reducing the potential for head and neck injury.

[0055]

[0063] From the above, it can be appreciated that the inclusion of the airbag wrap 100 within the airbag module 20, and the resulting deployment bias on the airbag 22, ensures that a significant portion of the energy used in the initial deployment of the airbag is not transferred to the occupant's head 40. This is evidenced by the large volume of the laterally inflated / deployed airbag positioned inboard from the occupant's head 40, resulting in a significantly smaller amount of head displacement. Advantageously, the airbag 22 can be inflated substantially laterally inward from the occupant 14 and transition to the normal inflated and deployed state of FIG. 7C laterally, significantly reducing the amount of deployment energy transferred from the airbag 22 to the occupant's head 40. This capability is particularly advantageous in the case of a steering yoke 50 that omits an upper rim portion.

[0056] Additional configuration

[0064] Although the illustrated exemplary airbag module 20 is configured to bias the airbag 22 to deploy laterally inward, it will be appreciated that the airbag module may be configured to bias the airbag to deploy in any desired direction in the vehicle. For example, the airbag module 20 may be configured to bias the airbag to deploy laterally outward rather than inward. As another example, the airbag module 20 may be configured to bias the airbag to deploy upward or downward (as viewed from the perspective of the occupant in FIGS. 6A-6B ). As a further example, the airbag module 20 may be configured to bias the airbag to deploy in any desired vertical / lateral direction.

[0057]

[0065] For example, Figure 8 illustrates an alternative configuration of an airbag wrap 100 that may be mounted to the airbag module 20. The airbag wrap 100 of Figure 8 is identical to the airbag wrap shown in Figure 3, and the reference numerals and associated descriptions described above with respect to Figure 3 also apply to Figure 8 and will not be repeated here. The airbag wrap 100 of Figure 8 may differ from the configuration of Figure 3 in that it may have a scalloped configuration. According to the scalloped configuration of the airbag wrap 100, the scallops 150 are formed by cutting curved edges 152 into the central portion 102.

[0058]

[0066] The purpose of the scallops 150 is to form the central portion 102 so that stresses on the airbag module cover 64 (see FIG. 2 ) when it is opened in response to airbag inflation and deployment, for example, are distributed or otherwise directed to avoid undesired tearing or crushing of the cover. At the same time, the airbag wrap remains effective in biasing the airbag 22 to initially deploy inward to provide protection to the OOP occupant, as described above. Comparing the example configurations of FIGS. 3 and 8 , the curved edges 152 of the scallops 150 in FIG. 8 are moved toward the center of the module cover 64 from the corresponding edges in the configuration of FIG. 3 . This configuration may help avoid crushing the cover 64 at the edges of the cover by shifting deployment forces toward the center of the cover 64.

[0059]

[0067] As another example, Figures 9A-9B show another alternative configuration of an airbag wrap 100 that may be mounted to an airbag module 20. The airbag wrap 100 of Figures 9A-9B may be identical to either the airbag wrap shown in Figure 3 or the airbag wrap shown in Figure 8, and the reference numbers and associated descriptions set forth above with respect to Figures 3 and 8 also apply to the configuration of Figures 9A-9B and will not be repeated here. The airbag wrap 100 shown in Figures 9A-9B has the scalloped configuration of Figure 8 and thus includes scallops 150 and scalloped edges 152 (shown only in Figure 9A). The airbag wrap 100 shown in Figures 9A-9B may alternatively have the non-scalloped configuration of Figure 3.

[0060]

[0068] The airbag wrap 100 of FIGS. 9A-9B differs from the configuration of FIGS. 3 and 8 in that it includes pleats 160 that assist in controlling the deployment of the airbag. The pleats 160 are formed by folding a portion of the lower portion 120 of the airbag wrap 100 over the central portion 102 of the wrap. This positions a pleated portion 164 of the lower portion 102 between the remainder of the lower portion and the central portion 102. The pleats 160 include tear stitches 162 that extend through the overlapping portions of the airbag wrap 100, i.e., the central portion 102, the lower portion 120, and the pleated portion 164, to secure these portions in the pleated condition shown in the figures. In this manner, the pleats 160 provide a good grip over the deployment opening 106, specifically the portion of the deployment opening adjacent to the pleat location, i.e., the deployment opening. The size of the lower portion of the opening is reduced.

[0061]

[0069] The tear stitching 162 is rupturable in response to airbag deployment forces acting on the airbag wrap 100. As the airbag 22 inflates and deploys through the deployment opening 106, which has been reduced in size due to the pleats 160, the deploying airbag acts on the airbag wrap 100, pushing it outward, away from the steering yoke 50, building tension in the pleats 160. This tension pulls on the tear stitching 162, which eventually ruptures, allowing the pleats 160 to open. As this occurs, the deployment opening 106 increases in size.

[0062]

[0070] During initial inflation and deployment of the airbag 22, the pleats 160 limit the extent to which the lower portion 120 of the airbag wrap 100 can move or open. The pleats 160 formed in the lower portion 120 of the airbag wrap 100 limit the opening of the deployment opening 106 (see, e.g., FIGS. 4, 5, and 7B) at the lower portion of the opening. This results in a restraint on the initial deployment of the portion of the airbag 22 that deploys through the lower portion of the deployment opening 106 (i.e., the lower portion of the airbag). When the deployment force acting on the airbag wrap 100 exceeds the tear strength of the tear stitching 162, the stitching releases, the deployment opening 106 fully opens, and the lower portion of the airbag 22 can deploy without this initial restraint.

[0063]

[0071] Initial restraint of this portion of the airbag 22 can be advantageous, particularly in the case of an out-of-position occupant, as described above, because this portion can be associated with a lower portion of the occupant's head 40, e.g., the chin. Removing the initial deployment force from this region can further increase the extent to which the energy used for the initial deployment of the airbag is not transferred to the occupant's head 40. The pleats can create an initial deployment path for the airbag 22 both laterally and upwardly relative to the occupant's head 40, particularly in the case of an out-of-position occupant. As the pleats 160 open, airbag deployment continues, but the deployment energy transferred from the airbag 22 to the occupant's head 40 is significantly reduced.

[0064]

[0072] From the above description of the invention, those skilled in the art will perceive improvements, changes, and modifications of the present invention. Such improvements, changes, and modifications within the scope of the art are intended to be covered by the appended claims. <Additional Notes> [Appendix 1] 1. An apparatus for assisting in the protection of a driver's side occupant of a vehicle having a steering yoke, comprising: an airbag attached to the steering yoke; an airbag wrap surrounding the airbag mounted to the steering yoke and configured to bias the airbag to deploy laterally relative to a steering axis of the steering yoke. [Appendix 2] 10. The device of claim 1, wherein the airbag wrap includes a deployment opening and pleats formed in the airbag wrap. [Appendix 3] 3. The device of claim 2, wherein the pleats are secured with tear stitches. [Appendix 4] 4. The device of claim 3, wherein the tear stitch is configured to break in response to deployment of the airbag. [Appendix 5] 5. The device of claim 4, wherein the pleats are configured to open in response to rupture of the pleats. [Appendix 6] 5. The device of claim 4, wherein the deployment opening is configured to increase in size in response to rupture of the pleats. [Appendix 7] 2. The device of claim 1, wherein the airbag wrap is configured so that as the airbag deploys through the deployment opening in an initial deployment direction, a biasing force exerted on the deploying airbag is reduced to a point where pressurization of the airbag overcomes the biasing force, causing the airbag to return to a normally deployed state toward the steering axis. [Appendix 8] 10. The device of claim 1, wherein the airbag wrap is further configured to limit movement of the airbag in a direction other than an initial deployment direction such that the airbag wrap biases the airbag to deploy through the deployment opening in the initial deployment direction. [Appendix 9] 10. The device of claim 1, wherein the airbag wrap is configured such that the deployment opening is at least partially defined by an edge of the wrap configured to disperse at least a portion of an initial airbag deployment force away from an edge of a cover behind which the airbag and the airbag wrap are stored. [Appendix 10] 10. The device of claim 9, wherein the edge of the wrap that at least partially defines the deployment opening comprises a scalloped edge. [Appendix 11] 10. The device of claim 9, wherein the scalloped edge comprises an edge that curves inward toward a central portion of the cover. [Appendix 12] 10. The apparatus of claim 1, wherein the airbag and airbag wrap are components of an airbag module, the airbag module further comprising: an inflator for inflating the airbag; and a retainer to which the inflator, the airbag, and the airbag wrap are secured, the retainer configured to connect to the steering yoke and mount the airbag module to the steering yoke. [Appendix 13] 13. The device of claim 12, wherein the airbag wrap comprises: a central portion configured to cover the airbag; a first wrap portion extending in a first direction from the central portion, wrapping around the airbag, the inflator, and the retainer, and secured to a back portion of the retainer; a second wrap portion extending from the central portion in a second direction opposite to the first direction, wrapping around the airbag, the inflator, and the retainer, and secured to the back portion of the retainer; a third wrap portion extending from the central portion in a third direction transverse to the first direction and the second direction, wrapping around the airbag, the inflator, and the retainer, and secured to the back portion of the retainer. [Appendix 14] 14. The device of claim 13, wherein the third direction is opposite to the initial deployment direction. [Appendix 15] 14. The device of claim 13, wherein the central portion and the first, second, and third wrap portions define the deployment opening and, by their respective connections to the back portion of the retainer, limit movement of the airbag in directions other than an initial deployment direction. [Appendix 16] 14. The device of claim 13, wherein the second wrap portion is folded to form pleats, and a tear stitch extends through the pleats to connect the folded portion of the second wrap portion to the central portion. [Appendix 17] 14. The apparatus of claim 13, further comprising fastener studs extending through the retainer and through fastener-receiving openings at ends of the first, second, and third wrap portions for securing the first, second, and third wrap portions to the retainer. [Appendix 18] 18. The apparatus of claim 17, wherein the fastener stud also secures the airbag and the inflator to the retainer. [Appendix 19] 10. The apparatus of claim 1, wherein the airbag has a generally circular, pillow-shaped configuration and a normal deployment position of the airbag is generally centered about the steering axis. [Appendix 20] 10. The device of claim 1, wherein the initial deployment direction is configured to be transverse to the vehicle. [Appendix 21] 10. The device of claim 1, wherein the initial deployment direction is configured to be laterally inward relative to the vehicle. [Appendix 22] 10. The device of claim 1, wherein the initial deployment direction is configured to be laterally from an area on the steering yoke where an out-of-position occupant's head may rest. [Appendix 23] 23. The apparatus of claim 22, wherein the airbag is configured such that deployment in an initial deployment direction directs the airbag's deployment energy away from an area on the steering yoke where an out-of-position occupant's head may rest. [Appendix 24] 24. The apparatus of claim 23, wherein the airbag is configured such that deployment in an initial deployment direction imparts an initial, low deployment energy to the OOP occupant's head, causing an initial, low-energy movement of the OOP occupant's head away from the steering yoke. [Appendix 25] 24. The apparatus of claim 23, wherein the airbag is configured to further move the OOP occupant's head away from the steering yoke after the initial deployment energy is dissipated by moving the airbag back toward the steering axis to a normally deployed state. [Appendix 26] 13. A vehicle safety system comprising the airbag module of claim 12.

Claims

1. 1. An apparatus for assisting in the protection of a driver's side occupant of a vehicle having a steering yoke, comprising: an airbag attached to the steering yoke; an airbag wrap surrounding the airbag mounted to the steering yoke and configured to bias the airbag to deploy in a single direction transverse to a steering axis of the steering yoke.

2. 10. The device of claim 1, wherein the airbag wrap includes a deployment opening and pleats formed in the airbag wrap.

3. 3. The device of claim 2, wherein the pleats are secured with tear stitches.

4. 4. The device of claim 3, wherein the tear stitch is configured to break in response to deployment of the airbag.

5. The device of claim 4 , wherein the pleats are configured to open in response to breaking of the tear stitches.

6. The device of claim 4 , wherein the deployment opening is configured to increase in size in response to breaking of the tear stitch.

7. 10. The apparatus of claim 1, wherein the airbag wrap includes a deployment opening formed therein, and wherein a biasing force exerted on the deploying airbag as the airbag deploys through the deployment opening in an initial deployment direction is reduced to a point where pressurization of the airbag overcomes the biasing force, causing the airbag to return to a normally deployed state toward the steering axis.

8. 10. The device of claim 1, wherein the airbag wrap includes a deployment opening formed in the airbag wrap, the device being further configured to limit movement of the airbag in a direction other than an initial deployment direction such that the airbag wrap biases the airbag to deploy through the deployment opening in the initial deployment direction.

9. 10. The device of claim 1, wherein the airbag wrap includes a deployment opening formed therein, the deployment opening being configured to be defined at least in part by an edge of the wrap configured to distribute at least a portion of an initial airbag deployment force away from an edge of a cover behind which the airbag and the airbag wrap are stored.

10. 10. The device of claim 9, wherein the edge of the wrap that at least partially defines the deployment opening comprises a scalloped edge.

11. 11. The device of claim 10, wherein the scalloped edge comprises an edge that curves inward toward a central portion of the cover.

12. 10. The apparatus of claim 1, wherein the airbag and airbag wrap are components of an airbag module, the airbag module further comprising an inflator for inflating the airbag, and a retainer to which the inflator, the airbag, and the airbag wrap are secured, the retainer configured to be connected to the steering yoke to mount the airbag module to the steering yoke.

13. 13. The device of claim 12, wherein the airbag wrap comprises: a central portion configured to cover the airbag; a first wrap portion extending in a first direction from the central portion, wrapping around the airbag, the inflator, and the retainer, and secured to a back portion of the retainer; a second wrap portion extending from the central portion in a second direction opposite to the first direction, wrapping around the airbag, the inflator, and the retainer, and secured to the back portion of the retainer; a third wrap portion extending from the central portion in a third direction transverse to the first direction and the second direction, wrapped around the airbag, the inflator, and the retainer, and secured to the back portion of the retainer.

14. 14. The device of claim 13, wherein the third direction is opposite to an initial deployment direction of the airbag.

15. 14. The device of claim 13, wherein the central portion and the first, second, and third wrap portions define deployment openings that, by their respective connections to the back of the retainer, limit movement of the airbag in directions other than an initial deployment direction.

16. 14. The device of claim 13, wherein the second wrap portion is folded to form pleats, and a tear stitch extends through the pleats to connect the folded portion of the second wrap portion to the central portion.

17. 14. The apparatus of claim 13, further comprising fastener studs extending through the retainer and through fastener-receiving openings at the ends of the first, second, and third wrap portions for securing the first, second, and third wrap portions to the retainer.

18. 18. The apparatus of claim 17, wherein the fastener stud also secures the airbag and the inflator to the retainer.

19. 10. The apparatus of claim 1, wherein the airbag has a generally circular pillow-shaped configuration, the airbag being generally centered about the steering axis in a normal deployed position.

20. 10. The apparatus of claim 1, wherein the airbag is configured to have an initial deployment direction transverse to the vehicle.

21. 10. The apparatus of claim 1, wherein the airbag is configured to initially deploy laterally inwardly relative to the vehicle.

22. 2. The device of claim 1, wherein the airbag is configured to deploy initially to the side of an area on the steering yoke where an out-of-position occupant's head may rest.

23. 23. The apparatus of claim 22, wherein the airbag is configured such that deployment in an initial deployment direction directs the deployment energy of the airbag away from an area on the steering yoke where an out-of-position occupant's head may rest.

24. 24. The apparatus of claim 23, wherein the airbag is configured such that deployment in an initial deployment direction imparts an initial, low deployment energy to the OOP occupant's head, causing an initial, low energy movement of the OOP occupant's head away from the steering yoke.

25. 24. The apparatus of claim 23, wherein the airbag is configured to move back toward the steering axis to a normal deployment state, thereby further moving the OOP occupant's head away from the steering yoke after the initial deployment energy has been dissipated.

26. A vehicle safety system comprising the airbag module of claim 12.

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