CA2005458A1 - Airbag module and method of making same - Google Patents

Airbag module and method of making same

Info

Publication number
CA2005458A1
CA2005458A1 CA002005458A CA2005458A CA2005458A1 CA 2005458 A1 CA2005458 A1 CA 2005458A1 CA 002005458 A CA002005458 A CA 002005458A CA 2005458 A CA2005458 A CA 2005458A CA 2005458 A1 CA2005458 A1 CA 2005458A1
Authority
CA
Canada
Prior art keywords
inflator
module
housing
inflator device
air cushion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002005458A
Other languages
French (fr)
Inventor
Jess Cuevas
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Talley Automotive Products Inc
Original Assignee
Talley Automotive Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Talley Automotive Products Inc filed Critical Talley Automotive Products Inc
Publication of CA2005458A1 publication Critical patent/CA2005458A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/20Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components
    • B60R21/217Inflation fluid source retainers, e.g. reaction canisters; Connection of bags, covers, diffusers or inflation fluid sources therewith or together

Abstract

AIRBAG MODULE AND METHOD OF MAKING SAME

ABSTRACT

An airbag module comprising a pyrotechnic inflator device; an inflatable air cushion operatively associated therewith; a retainer for lockingly engaging the air cushion to the inflator and a mounting plate configured and adapted for securing the inflator, the air cushion and the retainer in operative association. A variety of inflator embodiments may be incorporated into the module assembly but each requires, along at least a portion of the housing thereof, a rounded arcuate surface configured for engagement with the retainer upon the formation of a structural seal between the mounting plate and the retainer. This structural seal is created by magnaforming a portion of the mounting plate into a corresponding open groove upon the retainer. The module is thus fabricated by positioning the inflator upon the mounting plate; lockingly engaging the air cushion and the retainer;
lowering the retainer/cushion assembly over the inflator and magnaforming the wall of the mounting plate into the groove on the surface of the retainer.

Description

~os~s~ :

AIRBAG MODULE
AND METHOD OF MAXING SAME

Technical Field The invention relates to passive 6afety devices for installation within a motor vehicle and more particularly to a modularized assembly ~or ~ounting an air bag together with an inflation device therefor upon t~e st~ering wheel assembly of such a vehicle, Back~round of the Invention ': ~ .:
Pyrotechnic inflator devices utilizing solid combustible gas generant compositions are well known for use in motor vehicles such as automobiles to protect the operator thereof from injury occurring as a result of a collision between the subject vehicle and another object. An important consideration involved with installing such passive restraint systems, however, is how to arrange and position the device upon the steering wheel assembly thereof.
For reasons of styling and consumer acceptance, as well `
as not interfering with the driver's movement or his vision of ``
the instrument panel, and so as not to degrade the vehicle's steering dynamics, it is desirable to arrange a crash restraint apparatus as conveniently as possible, and yet have it positioned so that it effectively accomplishes its intended ; ~ `
protective function. In addition, since an inflator device for such a crash restraint system must be capable of discharg-ing a relatively large volume of gas in a very short period of time (i.e., within about 30-60 milliseconds), there are safety `~
considerations which must be taken into account, not only in the deployment of the inflator within the vehicle, but also with regard to handling, installing, replacing and repairing such devices.

20(:~545~

Moreover, in the particular case of ~ driver~c side, i.e., teering wheel, install~ltion within an automobile or a truck, for example, the utilization of an in~lator apparatus h~ving a r~latively low ma86 i6 important for æeveral reasons.
First, ~he ~teering wheel a6sembly i8 installed in a cantilevered po~ition at the end of the s~eering column, and thus exces~ive weight placed upQn this aQsembly can cause column whip, attributable to ~ertical accelerations due ~o road shocks (e.g., bumps or cl~uckholes) which may, in turn, lead to deyraded if not total lo~s of driver control.
Secondly, if for reasons such as styling or driver vision line clearance, the inflator is reguired to be located asy~metrically with respect to the steering column centerline, any exces6ive weight attributable to this device will create resistive wheel turning torque, thus degrading the rotational dynamics of the steering assembly and providing potential for loss of driver control or other undesirable vehicle handling "feel" under certain driving conditions.
Driver's side airbag inflator assemblies are thus conven- ;
tionally central}y located within the circumferential periphery of the vehicle's steering wheel. Typically, the terminal portion of the steering shaft adjacent the steering wheel is covered by a steel hub. This hub is connected by ~everal spokes to the rim of the wheel, utilizing fasteners such as bolts or screws in order to provide structural rigid-ity to the ~ssembly. In some cases a metal frame mounting plate or "spider" (so-called due to its arachnid appearance) is installed above the hub with its legs fa~tened to the wheel ~bove the spokes. The inflator is then mounted upon this ~pider, which has a central aperture configured to accept at least a portion of the inflator housing. Several variations of this arr~ngement are illustrated in, for example, U.S.
Patent nos. 3,827,7l5 to Lynch and 3,895,823 to Stephenson.
.

``- 2~ 5~3 In an alternate a sembly technigue practiced in the prior art, an upper "di~fuser" portion of the inflator is inserted through an aperture defined in a supporting frame member from the rear thereof. The inflator uni~ and ~he frame member are S then orient~d in a manner such that geveral apertures defined i~ flanged "ear" portions which extend from the generator hou6ing, are aligned with corresponding mounting apertures in the mounting plate. This arrangement thu6 permits these components to be fa~tened together by the u~e of a plurality o~ securing ~eans, such as bolts, rivets or screws which are passed through the generator ~ounting nears" and thereafter through the mounting plate.
Moreover, to retain an air bay in operative association with the inflator device, the bag is normally provided around its mouth portion wi~h a number of reinforced apertures. This ;
portion of the bag is then wrapped around a separate bag retaining ring, having a series of apertures corresponding to ` those through the bag mouth. The bag and ring assembly is then fastened using a second group of ~asteners, to the front -fac~ of the mounting plate. Alternately, the bag may simply be sandwiched between a retaining member and the front ~ace of the mounting plate w~th the fasteners passing through:
(1) the mounting plate, (2) the air bag and (3) the retaining member. In either event, a variety of time-csnsuming, labor intensive fastening operations must be undertaken in order to secure: (1) the inflator to the mounting plate and t2) the air bag to the ~ounting plate. Securing means, such as, ~or example, lock nuts, are utilized to prevent loosening of the fastener~ which connect the various components in operative alignment.
In addition, to protect the relatively fragile electrical leads which extend out of the bottom, i.e., ~losure, ~ember of the inflator housing (from the electrically activated ignition ~quib positioned therein), an additional component ~nown as a : . . ,, .,: . -. " : : - . ~ f . :; .: ,, , ~ , . :,. ~,. . .

~0~45~3 "wire ~hield", i~ typically screwed or bolted to the rear face of the ~ountinq pl~te, rearwarclly of the inflator unit, during ~he assembly procedure. The wires are routed throu~h an aperture ~n ~he diffus~r prov~ded therein for this purpose and thereafter through an open space in the wire shield to a remote colli~ion sensor locate~ elsewhere upon the vehicle.
This "wire shield" ~ember, reguiring a separate assembly step to install, is required to prevent the wires ~rom breaking off ~ro~ the Æguib if the inflator device is accidentally dropped or bumped during its asse~bly with the mounting plate or during installation within the steering mechanism of the vehicle.
The air bag is normally folded for storage and positioned on top of the diffuser portion of the inflator, which extends above the mounting plate through the mountinq aperture, where it remains until the passenger restraint apparatus is actuated. A cover member is then installed above the bag in order to hide the assembly from view and to improve the aesthetic appearance of the vehicle's interior.
To facilitate the installation and removal of airbag systems of the type described above, these assemblies have previously been produced in modular form, as described for example, in U.S. Patent no. 3,819,205 to Dunford et al. In a preferred embodiment of the Dunford et al. device, a support plate, generally conforming to the shape of the opening of a dished hub, includes extensions which overlie the spokes.
Offset flanges on the support member seat on embossments of the hub and are secured thereto by fa~teners inserted from the lower side o~ the hub.
The support plate mounts the gas generator, the diffuser, ~the air ba~, a container for the air bag, and an outer decora-tive closure which hidec the aforementioned components from vi~w. In addition, both the container and the closure are provided with H-shaped weakened, i.e., scored, portions which . :
.'. :.-_ 5 _ i L~ 5':
may be rea~ily ruptured to provide an openin~ so that the air bag can deploy therethrough when the gas generator is ac~uated~ The assem~ly of ~hese ~odularized components still, h~we~er, requires the insertion of ~ plurality of fastener ~ambers in order to maintain each part ~n operative alignment.

Summarx_of the Invention ~he present invention concerns an improved modular design for a motor vehicle passive restraint, i.e., air bag, as~embly, which may be utilized in a variety of forms of motor transport, e.g., automobile, van, truck, etc.
It is thus an object of the present invention to provide a modular zed air bag passive restraint assembly which may be constructed without the use of fasteners such as bolts or screws which are required in the prior art to maintain the various components of such a device in operative association.
It is a further object of the invention to make available an air bag module assembly having a built-in wire shield formed as a portion of the mounting plate therefor, thus eliminating a time-consuming ~ssembly step.
It is a ~till further object of the invention to provide a modular air bag system which may be assembled utilizing a minimum num~er of parts at a reduced number of work stations while in fact enhancing the strength of the bond among the various co~ponents.
~ t is another object o~ the present invention to design an air bag module assembly configured for the inclusion of a variety of inflator unit designs in which the only critical structural reguirement for permitting the integration of a partizular inflator into the module is the presence of a r 2 0 ~) 5 ~15 ~3 rounded shoulder portion upon the outer periphery of the inflator hou lng, typically in the zone where the closure and diffuser ~e~bere are joined together.
The pr~6ently claimed module aseembly is thus comprised of four pri~cipal components: ~n inflator device, a retainer ring, an in1~table air bag and a ~oun~ing plate. Inflator devices or u~e in applicant~ proposed module as~embly are preferably constructed o~ ~ rela~ively light-weight, corrosion resistant, high tensile strength material, such as aluminum or titanium, or alternately, certain light-weight ~tainless steels. Such inflators typically comprise an upper diffuser me~ber and a lower closure member for sealin~ the diffuser member, which together form the generator housing. Positioned within the housing is a solid, pyrotechnic gas generating compositi~n and a means for igniting the propellant, such as an electrically actuated squib, located adjacent thereto.
Interposed between the propellant and the inner surface of the diffuser is a ~iltering assembly for cooling the gas and removing molten particulates therefrom prior to its discharge through a plurality of exit ports in the diffuser, and into the attached air bag.
Applicant is aware of only two inflator embodiments hav~ng the requisite external rounded shoulder feature necessary to permit their inclusion into the module assembly of the present invention. These devices are described in applicant's co-pending patent applications entitled LIGHTWEIGHT NON-WELDED INFLATOR UNIT FOR AUTOMOBILE AIRBAGS
filed under ~erial no. 233,191 on August 17, 1988 and LIGHTWEIGHT NON-WELDED GAS GENER~TOR WITH ROLT~D SPUN LIP
filed under ~erial no. 246,065 on September 16, 1988. The disclo~ure of each of these applications is thus expressly incorporatecl herein by reference.

~5 7 - ~
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: :
Moreover, ~he air bag utilized with the present invention is further designed to have a locking bead within its mouth portion, which bead is compri~ed o~ an elastomeric O-ring capable of a limited degree of expan~ion and contraction, wrapped by the bag material and ~ubsequently sewn into place.
The locking bead i5 thus configured and adapted to fit into a first grooved portion along ~he upper outer 6urface of the retainer ring, which is positioned circumjacent ~o the inflator unit upon the mounting plate in the module assembly.
To effect this engagement, the locking bead is simply stretched over the flanged upper lip of the retainer and the mouth of the bag is then per~itted to contract back into the grooved portion thereof.
The flanged upper lip of ~he re~ainer ring serves to direct the hot gasses and particulates which exit the diffuser portion of the generator housing, through a plurality of diffuser ports along the periphery thereof, toward the central portion of the bag cavity and away from the stitched portion of the air bag to prevent damage thereto and to avoid a 2~ subsequent bag failure.
The mounting plate portion of applicant's module is ini-tially formed as an open pan, which is subsequently sealed by a cover portlon adapted to fit thereover, once the inflator air ~ag and the retaining ring have been locked therein. The moun~ing plate is constructed with several descending levels, or steps, which become relatively smaller in size as one pro-ceeds from the open "front" portion of the plate ~open, that is, prior to the installation of the cover member) to the closed "rear" portion thereof. As will be explained in detail below, each of these Rtepped portions serve a separate function.
Applicant's air bag ~odule i8 thus quickly and easily assembled in the following ~equence: first, the inflator is centered UpOII a second stepped portion of the mounting plate.

. .

-- Z~05~S8 Next/ the locking be~d within the bag ~outh is ctretched over the flanged upper lip of the retainer ring and thereafter per~itted to retract back into ~he first, i.e., upper, groove thereon. The retainer ~nd bag a~s~bly is then lowered over the diffuser portion o~ ~he inflator until the bottom portion of the reta$ner ring also res1:s upon the second s~ep, such that the r~tainer i6 circumjacent to ~he inflator. The bag is then folded for 6torage withill the first 6tepped portion of the mounting plate and therea~ter rests ~op the dif~user portion of the inflator housing.
Subsequently, the second ~tepped portion of the mounting plate is formed into a second grooved portion of the retainer ring defined by the lower outer surface thereof. This technique permits ~oth the bag and the inflator to be lS simultaneously locked into position within the mounting plate, within a matter of seconds, with no need for time-consumi~g and labor-intensive intermediate fastening steps.
As can be seen from the present disclosure, therefore, applicant's presently claimed module has a number of advantages over air bag assemblies existing in the prior art.
These include: -1. The opening of the air bag is simplified. The bag remains locked in place at all times as a result of the bead con~iguration;
2. The bag to inflator joint is stronger due to the full 360 contact therebetween:
3. Bag to retainer orientation is unnecessary, i.e., -~
there are no holes pierced in the bag for fastener retention;
4. There is no orientation required between the inflator nnd the mounting plate 8ince there are no fa~teners required for inflator retention:
5. There is no ~eparate wire ~hield device rRquired as in existing designs. Wire protection is "built-in"; and ;~

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20~ 5~3 :
6. Applicant~s en~ire module ~ay be as embled in approximately 10 ~econds.

Brief Description of the Drawin~s ~ IG. 1 is a perspective vi~w of applicant's airbag module;
FIG. 2 is a sectional ViQW taken through the mounting plate portion of the module o~ FIG. l;
FIG. 3 is a view, partially in section, of the internal arrangement of components within the module of FIG. 1 taken along line 3-3 of FIG. l; and FIG. 4 is a sectional view taken along line 4-4 of FIG.
3.
t5 Detailed DescriPtion of the Preferred Embodiments Referring initially to FIG. 1, there is illustrated the rearward face of applicant's module assembly 10. By "rear", "rearward", or "lower", therefore applicant means that portion of the assembly facing away from the driver. By extension, therefore, applicant will refer to the "front" or "upper" face of the asse~bly as that portion facing the driver of the vehicle. Thus, module 10, as illustrated in FIG. 1, externally comprises mounting plate 12 and cover portion 14.
Cover 14 is used to seal the open end of plate 12 and to hide the contents thereof from view.
The recent emphasis on weight reduction for the purpose of fuel conservation in motorized vehicles, has created a need ;
and a d~mand for a lighter weight passive restraint system.
This is of particular importance in a crash protection system for the driver wherein the inflator is mounted on the vehicle's st~ering wheel. Plate 12 is thus preferably fabricated from a metal stamping, since this process is both ;~054S8 quick and inexp~-nsive. In the preferred embodiment, plate 12 is formed of aluminum in srde:r to minimize the weight of m~dule 10. The availability of a lighter weight inflator for installation at this location furt~er enables a reduction to be ~ade in the weight of the ~ehicle's Rteering wheel and the steering column on which ~he :inflator is mounted, leading to a concurrent improvement in ~he ns~eerability" of the automobile.
Cover 14, is formed of ~ soft, flexible material, e.g., a urethane (such as polyurethane) or an engineering plastic, which is preferably colored and/or decorated (at least on its front face,) to enhance the aesthetic appearance of the steering wheel assembly. ~over 14 is preferably maintained in position upon mounting plate 12 either by angaging the upper 15 peripheral edge of plate 12 or by equipping plate 12 along its `~;
upp~r, open end with a double wall thickness, that is, an inner and an outer wall with a space in-between, and forcing a compressible peripheral edge portion of cover 14 into the space between the walls, wherein it is held by compressing the ;~
walls toward each other or by crimping.
In the preferred embodiment, cover 14 is scored, prefer~
ably in an H-shape along its front face, to facilitate deploy- ~ `~
ment of the air bag once the inflator is actuated. Thus, in the subject embodiment, cover 14 bursts at the score line as `
the bag is inflated, forming upper and lower flap portions which are pushed out of the way to permit expansion of the air ~`~
bag as the combustion of the gas generant proceeds within the in~lator. ~ `~
Mounting plate 12 is configured with a series of stepped portions 16, 17, 18 which are of relatively diminishing si~e ~from the front of the plate to the rear thereof. Steps 16, 17, 18 each perform a separate function, i.e., they ~re`~`
configured ~nd adapted to permit insertion within plate 12 of a pyrotechnlc air bag inflator device and to facilitate a :
. " ~.
~ ~

2~05a~58 ~-. . .

6ubseque~t locking engagement therewith. Plate 12 thus comprises a ~ir~t ~tepped region 16, deined by outer wall 16a and ba~e portion 16~; second stepped region 17, defined by outer circumferential wall 17a ~nd base 17b, said base 17b configured to 8Upport a fl~t lower surface of a pyrotechnic infl~tor device (ns illustra~ed in FIG. 3) and a third stepped region 18, de~ined by outer circumferential wall 18a and base 18b.
Region 18 serves ~s ~n integral wire shield for protecting electrical leads 22a,b of module 10 from damage due to mishandling of the inflator during assembly. ~oreover, although stepped regions 17, 18 are shown as being circular in shape, they may be configured in other geometric shapes so long as it is understood that second stepped region 17 must be shaped to permit insertion therein of an inflator unit of the type contemplated for use with module 10.
Wire shield 18 is positioned and configured at the base of module 10 to prevent, as noted above, inadvertent damage to electrical leads 22 a,b extending from an igniter component (not shown), such as an electrically actuated squib, which is operatively positioned within the inflator to initiate combustion of the propellant charge therein upon a collision signal produced by a remote sensing device. Shield 18 further defines at least one aperture 20 which is configured to permit the passage of leads 22 a,b out of module 10.
Plate 12 further comprises, on the rear or lower face thereof, a plurality of stud members 24, preferably four (4) in number extendin~ perpendicularly to base portion 16b for a distance of ~bout one inch. Studs 24 are preferably press fit into each of the four corners o~ plate 12 and are threaded to permit attac~ment between module 10 and an underlying ~rame portion of the vehicle's ~teering assembly, which attachment procedure will be described below in detail.

~)Sf~5~3 FI~. 2 provides ~ ~ectional view of mounting plate 12, illustrating the 6tepped conf:igura~ion there~f as it appears prior to the for~inq o~ outer wall 17a around the inflator unit (di~cussed below). Mount:Lng plate ~2 ~hu~ initially presen~ the app~arance of an open pan configured ~uch that outer per~pheral wall 17a of l~econd R~epped portion 17 lies circumjaoent the inflator hou~ing (a~ ~hown ln FIG. 3) while base portion 17b i5 con~igurecl to support a lower or "closure"
member of the infla~or co~pri~;ing the bottom portion of said housing. ~n additlon, aB ~ay be noted from ~he drawing figure, wall 17a is initially configured in a substantially ~ :
straight vertical line prior to the ~odule forming step.
Further, as discussed a~ove, wall 18a, de~ining the circumferential periphery of ~tepped region 18, has at least one aperture 20 therethrough, which is configured for the passage ~f electrical leads 22a,b from the igniter, i.e., :-~
squib.
Turning now to FIG. 3 there is illustrated a sectional . .
view through applicant's module lo subsequent to the complete . ;~ ;
20 assembly thereof, involving the wall-forming step discussed in .
regard to FIG. 2. One important factor must be taken into account, however, concerning the configuration of inflator 26 which is included ~s a component of module 10. Whereas the internal arrangement of p~rts within inflator 26 is not a critical feature of the present invention, module 10 does require, $n order to ensure ~n immovable locking engagement between inflator 26 ~nd mounting plate 12, that inflator 26 h~ve a rounded shoulder on at least a portion of itC exterio.r ::
Gurface as ~hown, for example, at 28. In the preferred :
30 embodiment, 8houlder 28 extends completely around the outer -periphery of inflator 26 at the ~uncture of the diffuser and ~ :~
the closure member, which together form the inflator housing. : :
In alt~rnate e~bodiments, however, a housing for inflator 26 :

5~5~3 ~ay be formed in a different sh~pe, e.g., a square, rectangle, etc. ~nd/or shoulder 28 may extend along only a portion of the peripheral edge of inflator 26.
Moreover, as noted in the Summary portion of the present application, applicant i5 aware of only two inflation devices having the reguisite ex~ernal con~iguration, i.e., shoulder 28 ~de~cribed below in detail), ~nd ~he disclosure of applicant's copending p~tent applications directed to these embodiments has been incorporated herein by reference. Both of these novel in~la~or types are constructed according to new techniques which do not require the use of welds to maintain ~ -the structural integrity of these units. The present invention should not, however, be limited only to use with these inflators, or to non-welded inflators in general, although these are the preferred type.
In assembling module ~0, air bag 30 is designed with locking bead 32, comprising an elastomeric O-ring. The O-ring is wrapped by the bag material and thereafter sewn in place within the mouth of the bag.
Also required is retainer ring 34 which is formed of a strong, lightweight metal forging, preferably constructed of aluminum du~ to its relatively low weight. Retainer xing 34 is configured and adapted to fit over and thereafter around inflator 26. Ring 34 is comprised of a first (upper) grooved portion 38, a second (lower) grooved portion 36 and an upper deflector flange 40 for preventing the impingement of hot gasses ~nd/or ~olten particulates produced by the firing of inflator 26 directly upon the ~ewn portion of bag 30.
Flange 40 thus preserves the integrity of bag 30 during the inflation step wherein the aforesaid hot gasses and/or molten particulates, produced as result of the combustion of a solid gas g~nerant within in~lator 26, would otherwise exit diffuser ports 42 and impinge directly upon the inner surface of the bag. In the present arrangement, the particulate-. :` . . ' ` ' . .. `` . .

2 ~ 8 containing gasses initially encounter ~ngled flange 40 upon : -~xiting through diffuser port~; 42 ~rom inflator 26, and are thereafter directed upwardly and away from the sewn portion of bag 30 toward the center of the b~g.
Groove 38, located along the upper outer ~ur~ace of retainer ring 34, i6 thUS con~igured to ~ccept locking bead 32. There~ore, once inflator 26 is centered on ~econd stepped :
portion 17 of mounting plate 1~, bead 32 in bag 30 is :~
~tretched over deflector flange 40 on ring 34 and the retainer ring and bag assembly i6 then lowered over inflator 26 such that the lower surface of ring 34 rests on surface 17b, thus ~- :
positioning ring 34 circumjacent inflator 26.
Ring 34 is further configured, inwardly from upper groove 38, to engage rounded shoulder portion 28 of inflator 26 so as to lock inflator 2S within mounting plate 12 when lateral wall 17a thereof is formed into lower groove 36. This engagement ~
is facilitated due to the presence of angled wall portion 44 :~:
located along an inner portion the upper surface of annular ring 34, adjacent groove 38. Angled wall 44 is thus configured to overlie and abut against shoulder portion 28 of inflator 26 as ring 34 is ~queezed inwardly by the forming process. ~
Thus, by forming wall 17a into groove 35, a two-fold ::
purpose is 6erved: (1) the beaded portion 32 of bag 30 is locked into position within groove 38 on retainer ring 34, and (2) ring 34 and inflator 26 are also locked into position within mounting plate 12 due to the constriction created by forming wall 17a of plate 12 into groove 36. The cooperating ~fect between rounded shoulder portion 28 on inflator 26 and 30 angled wall portion 44 on the inner sur~ce of ring 34 ~-there~ore guarantees that retainer ring 32 will retain inflator 26 ~ithin module ~ounting plate 12 when applicant's passive restraint device, i.e., comprising module 10, is actuated. Thus, each of the components of ~odule 10 are .

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locked into place ~imultaneously by a 6ingle forming operation which may be performed in a matter of 6econd~ without the need ~or lo~ating and aligning numerous fasteners such a~ was previou~ly required by ~he prior art.
Wi~h r~gard to the technique re~erred to above, wherein w~ll 17a is ~formedn into lower groove 36 in retainer ring 34, applicant prefer~bly utilizes a procedure known as ~magnaform-ing" to ef~ect ~he requi6ite connection between the module co~ponents. This technique i~ de6cribed, for example, in U.S.
Patent no. 2,976,907 to Harvey et al. (the n~9o7 patent"), the disclosure of which is incorporated herein by reference.
Applicant has further determined that, with the use of the subject magnaforming technique, the temper of the metal of which the components of module 10 are formed should be as high as possible without being such that the metal cracks during the magnaforming process due to excessive brittleness. This ensures that module 10 may be constructed of lightweight materials, 6uch as aluminum for example, while still maintain-ing a sufficient degree of structural ~trength to withstand the forces generated during actuation of inflator 26.
By the use of a magnaforming process such as that described in the '907 patent, a variable magnetic field is first created outwardly ad~acent the work piece, e.g., the second stepped portion 17 of mounting plate 12. Subsequently one or more force impulses set up by this force field are ~ocused upon that portion of wall 17a on plate 12 overlying lower groove 36 defined by retainer ring 34. The effect of these force impulses is to al~ost instantaneously permit the 6ubject portion of wall 17a to ~low into groove 36 and thus to lock inflator 26, air bag 30 and retainer ring 34 together into a 6ingle unit in a ~atter of ~econds. There i5 thus no n~ed to phy ic~lly contact wall 17a of plate 12 with any mechanical device in order to create a 6trony structural ceal between the components of module assembly 10.

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,: :: - . - : . . . . .

2~5~5~
~odul~ ~sembly 10 additionally comprises, as noted ~ ::
~bove, a plur~lity of threaded fi~ud ~embers 24, preferably ~our (4) in number, which ~ay be press ~it into each corner portion on the rear ~ace of ba~e portion 16b. Studs 24 are S approxi~at~ly one inch in length and are inserted, during install~ti~n of ~odule 10 on the vehicle steering assembly, through corresponding apertures defined in an underlying metal ~rame or n~pider" fastened directly to the steering wheel of ~:
the vehicle (not shown) below ~odule 10. The subject spider :~
is further configured with a central aperture to permit clearance ~or the third stepped portion 18 of mounting plate 12. Module assembly 10 is thereafter maintained in contact relation with the underlying spider with the use of fastener `
means suc~ as a weld or locking nuts, which prevent withdrawal ;
of studs 24 from their corresponding aperture in the spider prior to or during operation of inflator 26. ~`:
Thus, after magnaforming the component parts of modul~ 10 ::~:
so as to lockingly engage bag 30 and inflator 26 within : :
mounting plate 12 by means of retainer ring 34, air bag 30 is neatly folcle~ and placed atop the diffuser portion of inflator 26. Then the completed module assembly is bolted in a single operation t~ a frame, i.e., the "spider", connected directly to the vehicle's steering assembly. Finally, to complete the assembly, aover member 14, which is preferably pre-scored to facilitate the passage therethrough of air bag 30 upon its deploymen~ during a collision, is snapped into place over the air bag with the aid of ~lexible members 46 extending. ~
perpendicularly therefrom to hide the various components of ~ : :
~odule 10 from sight and thus to enhance the aesthetic ~.
30 appearance of the vehicls'~ interior. ~:
FIG. 4 provides a ~ectional view through lower groove 36 in retainer ring 34. A6 ~ay be seen from the illustration, the magnaforming technique utilized by ~pplicant produces a continuous, even flow of metal wall 17a into groove 36. Thus ` ~ :

-~ 2~105~5~
17a i~ conformed to the s~pe of ~he groove. This process deforms the subst~ntially ve~:ical wall 17a and leads to the formation of upper 17a' ~nd lower 17a~ shoulder portions, Qeparated by groove 36 having w~ll 17a formed therein, on second ~tepped portion 17 of ~odule 10. As noted above, this procedure ef~ectively lo~ks pl~te 12 and ring 34 together which, in turn, ~aintains inflator 26 in position within ~odule 10 due ~o the pressure of ~ngled wall portion 44 ~gainst rounded ~houlder portion 2a of the inflator.
While it is apparent that the invention herein disclosed is well calculated to fulfill the objectives stated above, it will be appreciated that numerous modifications and embodi-ments may be devised by those skilled in the art. It is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.

, . . . . . . . ~
: --, ~ . . .. -. :: ~ ~ , . . - . . .

Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A motor vehicle airbag module which comprises:
(a) means for mounting a pyrotechnic inflator device within a passenger compartment of said motor vehicle, said inflator device being capable of producing a sufficient amount of a gaseous combustion product within a sufficient time to substantially deploy inflatable air cushion means operatively associated therewith within an interval between a primary collision of said vehicle with an object external thereto and a secondary collision between an operator of said vehicle and an interior portion thereof, said mounting means comprising an open pan having several stepped levels extending rearwardly thereon, each said level positioned directly over a next rearward one of said levels and having substantially the same depth at any point thereon, said levels correspondingly decreasing in relative volume from one located most forwardly to one located most rearwardly upon said mounting means;
(b) a pyrotechnic inflator device positioned within said mounting means, said inflator device comprising a housing formed of a diffuser member having a first open end and a second closed end and a closure plate member sealing said open end thereof, said housing further comprising an arcuate surface extending along at least a portion of an outer periphery thereof, said arcuate surface configured and adapted to permit a locking engagement between said mounting means and said inflator device;
(c) means for retaining inflatable cushion means in contact relation with said inflator device, said retaining means installed within said mounting means in surrounding relation to said diffuser member and configured to correspond to the external shape thereof; and (d) inflatable air cushion means for preventing injury to an occupant of said vehicle caused due to contact with said interior of said vehicle upon the occurrence of said primary collision, said inflatable means comprising means located within a mouth portion thereof configured to facilitate locking engagement between said air cushion means and said retaining means upon assembly of said module, wherein at least a portion of said mounting means is lockingly engaged within a corresponding open channel extending along at least a portion of an outer surface of said retaining means such that said inflator device, said inflatable air cushion means and said retaining means are all maintained together in operative association within said mounting means without the use of fasteners.
2. The module of claim 1 wherein said mounting means is lockingly engaged within said open channel by a structural seal formed therebetween; said seal created by magnaforming a peripheral wall portion upon one of said stepped levels of said mounting means such that said wall portion is formed into said open channel.
3. The module of claim 2 wherein said mounting means is a metal stamping which comprises, in series, a first, a second and a third stepped level extending rearwardly thereon, each said level completely overlying a next rearward one of said levels and comprising a base portion and an integral peripheral wall portion formed substantially perpendicular thereto, said peripheral wall portion of each said level extending entirely around an outer periphery of said corresponding level and being of a substantially unvarying width therealong such that each said level has a substantially constant depth at any point thereon.
4. The module of claim 1 further comprising means for covering said open portion of said mounting means, said covering means configured and adapted to engage at least a portion of an upper peripheral surface of said mounting means.
5. The module of claim 4 wherein said means for covering said open portion of said mounting means is a cover member formed of a relatively flexible material selected from a urethane and an engineering plastic, said cover member comprising a substantially planar top portion having first and second opposed surfaces and at least one means for lockingly engaging said mounting plate, said locking means formed integral with and extending substantially perpendicularly from said second surface of said top portion, wherein said top portion of said cover member is scored along at least a portion of said first surface thereof, to facilitate deployment of said inflatable cushion means upon actuation of said pyrotechnic inflator device.
6. The module of claim 1 wherein said pyrotechnic inflator device includes:
(a) a domed diffuser member, having a first open end and a second closed end;
(b) a closure plate member sealing the open end of said diffuser member and thereby forming an inflator housing;
(c) a sufficient amount of a combustible gas generant material located within an interior portion of said housing to produce, upon combustion thereof, a volume of a gaseous product sufficient to substantially inflate said air cushion means operatively associated therewith within about 30-60 milliseconds;

(d) means for initiating combustion of said gas generant material, said initiating means located within said inflator housing adjacent said gas generant; and (e) means located within said housing for filtering said gaseous combustion product prior to its discharge from the inflator housing, said filtering means circumferentially surrounding said gas generant material adjacent an inner wall portion of said housing and adapted for cooling said gas and removing substantially all particulate matter therefrom, said closure plate member and said domed diffuser member being sealed together without welding either of said members to form an inflator housing capable of withstanding elevated pressures produced by combustion of said gas generant material.
7. The module of claim 6 wherein said open end of said diffuser member comprises a peripheral lip portion, said lip portion being sealed over an outer circumferential edge of said closure plate member by magnaforming said lip portion over said edge.
8. The module of claim 6 wherein said pyrotechnic inflator device further comprises a ring-shaped member configured and adapted for snap-locking engagement with a rolled lip portion of said diffuser member against a bottom surface of said closure member, said locking member further comprising a notched edge portion along an outer surface thereof; said notch configured to engage at least an outer terminal end of said rolled lip.
9. The module of claim 6 wherein said means for filtering said gaseous combustion product comprises a plurality of screen members, said screen members being of relatively decreasing mesh size from an inner portion of said filtering means adjacent said gas generant to an outer portion thereof adjacent said inner wall portion of said housing, said filtering means configured to form a tortuous exit path for said gas and adapted to cool and filter substantially all said particulate matter therefrom.
10. The module of claim 9 wherein said domed diffuser member further comprises a plurality of diffuser ports spaced substantially equidistantly around a peripheral portion thereof, said ports providing fluid communication between the interior of said housing and an inner space defined by said inflatable air cushion means operatively associated therewith to permit deployment of said air cushion means upon the combustion of said gas generant material.
11. The module of claim 1 wherein said arcuate surface comprises a rounded shoulder portion upon said inflator housing, said shoulder extending along at least a portion of an outer surface thereof and having a diameter greater than a remaining portion of said housing, said shoulder configured and adapted to permit a locking engagement between said inflator device and said retaining means within said module.
12. The module of claim 1 wherein said retaining means is an annular metal forging having an upper and a lower, opposed surface, said retaining means comprising:
(i) a first grooved portion adjacent said upper surface thereof, said first groove configured and adapted for locking engagement with said mouth portion of said inflatable cushion means; and (ii) a second grooved portion adjacent said lower surface thereof, said second groove configured and adapted for forming a structural seal with said outer peripheral wall comprising said second stepped level of said mounting plate, said seal produced by magnaforming said outer peripheral wall of said second level such that said wall is formed into said second grooved portion.
13. The module of claim 12 wherein said retaining means is constructed of a light weight, high-tensile strength material and wherein said retaining means further comprises:
a) flanged means formed integral with said upper surface for directing said gaseous combustion products away from an interior surface of said inflatable air cushion means and toward an inner space defined thereby; and b) an angled wall portion extending along at least a portion of an inner annular surface of said retaining means, said angled wall portion adapted to overlie said arcuate surface upon said inflator device and thereby to retain said inflator within said module upon the formation of said structural seal.
14. The module of claim 1 wherein said inflatable air cushion means further comprises a flexible locking bead secured within the mouth portion thereof, said bead configured for locking engagement of said mouth within said first grooved portion of said retaining means.
15. A method for constructing the motor vehicle airbag module of claim 3 which comprises:
(a) positioning said pyrotechnic inflator device upon the second stepped level of said mounting means;

(b) securing a flexible locking bead within said mouth portion of said inflatable air cushion means;
(c) stretching said locking bead over an upper portion of said retaining means and into a first upper grooved portion defined thereby to form a retainer/bag assembly, said retaining means configured for installation adjacent said inflator device upon said mounting means, in surrounding relation to said inflator;
(d) lowering the retainer/bag assembly over at least an upper diffuser portion of said inflator device such that a lower base portion of said retaining means rests upon said second stepped portion of said mounting means circumjacent to said inflator device;
(e) forming a structural seal between the peripheral wall portion of said second stepped level upon said mounting means and the open channel of said retaining means, said open channel situated relatively rearwardly from said first grooved portion, said structural seal produced by magnaforming said peripheral wall portion such that said wall portion is formed into said open channel;
(f) folding said inflatable cushion means upon an upper diffuser portion of said inflator device for storage within said first stepped portion of said mounting means; and (g) securing a cover member to an upper peripheral portion of said mounting means, said cover member configured to conceal said retainer/bag assembly from view and to enhance the aesthetic appearance of said module.
CA002005458A 1988-12-27 1989-12-13 Airbag module and method of making same Abandoned CA2005458A1 (en)

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US07/290,544 US4913461A (en) 1988-12-27 1988-12-27 Airbag module and method of making same

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JP (1) JP2721719B2 (en)
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Publication number Publication date
JP2721719B2 (en) 1998-03-04
US4913461A (en) 1990-04-03
EP0376564B1 (en) 1993-09-08
DE68909027D1 (en) 1993-10-14
DE68909027T2 (en) 1994-04-07
EP0376564A1 (en) 1990-07-04
JPH03121950A (en) 1991-05-23

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Effective date: 19920614

FZDE Discontinued

Effective date: 19920614