Many vehicles utilize a thin inflatable airbag which, when inflated, is located proximate the sides of the passenger compartment to protects the upper torso and head of the vehicle occupants. These airbags are called "curtain"airbags and are typically mounted proximate the roof rail of the vehicle. The length of the airbag will vary with the application. Some curtain airbags are only long enough to cover a window while others extend between sets of windows and cover adjacent vehicle support structures such as the A, B, C and/or D pillars of the vehicle.

The curtain airbag is inflated by a conventional airbag inflator. The inflator communicates with an inlet of the airbag in a conventional manner.

The curtain airbag can be constructed utilizing many techniques. For example, two separate panels can be sewn together or the panels can be joined by a radio frequency weld or similar technique. The airbag can be constructed as a one-piece, integrally woven airbag utilizing a known Jacquard weaving process. Each of the above techniques can be used with the present invention.

Figure 1 is a plan view of the airbag of the present invention.

Figure 2 is an enlarged view of a portion of the airbag of Figure 1.

Figure 3 shows the airbag in an inflated state.

Figure 4 is a cross-sectional view at line 4-4 of Figure 3.

Figure 5 is a cross-sectional view at line 5-5 of Figure 3.

Figure 5a is a cross-sectional view at line 5a-5a of Figure 3.

Figure 6 is a cross-sectional view at line 6-6 of Figure 3.

Figure 7 is an enlarged view of the connection of a single inflator to a plurality of bag inlets.

Figures 8 and 9 show alternate embodiments of the invention.

Figure 10 shows a folded curtain airbag assembly mounted proximate a roof rail of a vehicle.

Figure 1 illustrates part of an airbag assembly 20 according to the present invention. The airbag assembly 20 includes an airbag 30. Preferably the airbag 30 is manufactured utilizing a Jacquard loom. The benefit of using a Jacquard loom is the airbag 30 is almost fully formed (finished) as it exits the loom with the exception of trimming the border of the airbag and perhaps slitting or opening the inlet or inlets of the bag. Alternatively the airbag 30 can be constructed by sewing or utilizing radio frequency welding techniques to join two separate panels of material together.

Figure 1 shows the airbag 30 in an inflated state, while Figure 3 shows the airbag 30 inflated and situated within a passenger compartment 202 of a vehicle 200 adjacent a side 204 of the vehicle. The side 204 represents the passenger side of the vehicle. A similarly constructed curtain airbag will also be positioned along an opposing side of the vehicle.

The airbag 30 includes at least one inflatable region 32 and at least one inlet 35 configured to communicate inflation gas received at the inlet to the inflatable region 32. An inflatable region 34, when inflated, is across the front side window 216 of the vehicle as shown in Figure 4. In one embodiment the curtain airbag 30 includes another or second main inflatable region 34. The inflatable regions 32,34 are positioned on either side of an uninflatable region or area 36. Additional inflated and inflatable regions can be added to the airbag. In the illustrated embodiment the airbag 30 additionally includes a second inlet 38 in fluid communication with an inflatable region 34. The construction and placement of the regions 32,34, 36 are more clearly shown in Figure 4, which is a cross-sectional view of the inflated airbag 30. Each of the main inflatable regions 32,34 is formed by two opposing panels 40,42 of fabric. The airbag 30 is preferably constructed utilizing a one-piece weaving technique utilizing a Jacquard loom. With a Jacquard loom the panels 40,42 are automatically formed during the weaving process and include fewer threads than in the joined-together regions of the airbag 30, such as the border regions and the inflated regions of the airbag.

Depending upon the desired permeability through the panels, the airbag can be coated with urethane, silicone, or a similar substance after it is woven or each panel can be coated prior to attachment to the other.

In Figure 1 the dotted lines 50,52 represent the location of sewn seams, which are used to attach separate panels of fabric 54,56 to selected portions 58,60 of the airbag 30. The panels 54,56 operate as anchors or tethers to connect these selected portions 50,52 of the airbag to cooperating parts of the vehicle 200 as shown in Figures 3 and 4. Fasteners 70,72 may be used to secure the panels 54,56 respectively to parts of the vehicle frame.

Each triangular tether or anchor panel 54 is sewn along the seam 50 to the airbag 30. The opposite end 55 of the panel 54 is secured to the A-pillar 210 of the vehicle. The panel 56 is also triangular in shape and the end 57 of the panel 56 is secured to the C-pillar 212 of the vehicle. In the illustrated embodiment the end of the panel 56 is secured proximate the side 37 of the inflated region 36. In Figure 4 the tether or anchor panel 56 is positioned between that portion of the airbag forming the second inflatable zone 34.

When inflated the anchor panel 56 will be positioned in front of the vehicle window 214 as shown in Figure 4. The panel 56 acts as a net or barrier preventing the vehicle occupant from being ejected from the vehicle. The tether panel can also be located at the end of the rear of facing side 64 of the airbag.

In Figure 1 a plurality of tabs 80 are formed as part of the upper border 82 of the airbag 30. Each of the tabs 80 includes a central region 84 connected to the upper border 82 as well as two opposing side regions 86.

Each of the side regions 86 of each tab 80 is connected to a corresponding center region 84 of the tab 80, however, in the preferred embodiment each lateral region is disconnected from the upper border 82. Each side region 86 of a tab 80 is folded about a corresponding fold line 87 and positioned behind the center portion 84 of the tab 80. The center portion 84 and the two folded- back side regions 86 form three layers of material increasing the holding strength of the tab 80. Figure 3 shows a plurality of tabs 80 mounted to the roof rail 220 of the vehicle and an individual fastener inserted through the triple thickness of tab material and then secured to the roof rail or mating threaded connector previously inserted in the roof rail. In Figure 1 the rearmost tab 80a includes the center portion 84 and one lateral tab 86, which is folded rearward about fold line 86 prior to receipt of a fastener 90.

The airbag 30 has two inlets 35,38. Figure 7 shows an enlarged portion of the inlet area of the airbag 30 and more particularly shows the connection of the two inlets 35,38 and the inflator 100. The inflator 100 can be any of a known variety of airbag inflators and has one or more exit ports 102. The exit port ports 102 communicate through a connection tube 104 to the inlet 106 of a tee-connector 108. The tee-connector 108 has outlets 110a, 110b that each communicate with one of the inlets 35,36 of the airbag.

In Figure 1 the airbag 30 includes one inflatable region 32 or, as illustrated, a plurality of inflatable regions 32,34 separated by an inflated region 36. Part of the regions 32,34 are formed in part by borders 46,46a, 46b, 82, which are integrally formed on the Jacquard loom during the weaving process. The inflatable region 32 includes a plurality of restrictions 120, which extend upwardly from the lower border 46 and which are also formed during the weaving process. Each restriction 120 forms a small uninflatable region and is formed in the same manner as region 36. The purpose of each restriction 120 is to narrow the distance between the lower portions of panels 40,42, narrowing the lower portion of inflatable region 32.

The inflatable region 32 includes another set of restrictions 124, which extend from a side border 46a or 46b) and/or upper border 82 and are generally positioned along the top of the inflatable region 32. The region 32 may include another type of restriction 126, which does not extend to or from the upper border 82 but which connects the panels 40,42 in the upper extremes of the inflatable region 32. The restriction 126 is positioned near an inlet 35 and defines a plurality of flow paths 130 to direct the flow of inflation gas from the inlet 35 to the inflatable region 32. The airbag 30 may have the restrictions 120,124, 126 expand generally from a peripheral border. For illustration only, Figure 1 shows additional restrictions 120'extending from the side borders of region 32.

Figure 2 illustrates the construction of one of the restrictions 120,120', 124,126. Each restriction includes a stem 140, which extends from a proximate border region 46,48a, 46b, 82. The restrictions, such as 120, include an enlarged region or head 142. In a preferred embodiment the thickness of the stem 140 is approximately 3-5 mm while the head 142 is in the range of approximately 30 mm. The stem includes a radiused or arcuately shaped base portion 144, which extends from the border regions of the airbag. The arcuately shaped base region 144 avoids concentrating forces into a narrow area. Preferably, the airbag 30 is manufactured utilizing a Jacquard loom ; consequently the restrictions are also interwoven structures.

Alternatively, the restrictions 120,124, 126 can be sewn into the airbag, thereby joining the opposing panels 40,42 together. If a sewn seam were used, its shape would follow the shape of the stem and head of each restriction shown in Figures 1 and 2. The enlarged head serves as a pressure relieving mechanism to avoid concentrating forces on narrow portions of the airbag, which might damage the airbag as its internal pressure increases.

In Figures 5 and 5a the greatest separation between the panels 40,42 is in a central portion of the inflatable region 32, which by design will correspond to the location of the seated occupant. For example, points 150, 152,154 show the impact point of the head of occupants respectively categorized as fifth, 50th and 95th percentile occupants.

The restrictions 120,124 and 126 also assist in defining the shape of the inflated airbag. If the airbag 30 did not include the peripheral extending restrictions, upon inflation, region 32 would approach the shape of a circular cylinder. As the airbag becomes more inflated, the lower edge of the airbag will move upwardly as the region assumes its more circular inflated shape.

This upward movement might sufficiently displace the airbag so that it does not effectively cushion the occupant. Most of the restrictions 120,122, 124 face the centrally inflated portion 160 of the inflatable region 32. This configuration permits those portions 162 between adjacent restrictions to be filled quickly.

The rear inflatable fion 34 is of similar construction to the forward inflatable region 32. The region 34 includes a plurality of restrictions such as 120,124, a major inflatable region 164 proximate the center of region 34a and a plurality of minor inflatable regions 166 located between adjacent restrictions and borders.

In Figure 1 or Figure 3 the inflatable regions 32,34 are linked by a common passage 170 located beneath the inflated region 36 to facilitate the exchange of inflation gas between inflatable regions 32,34. The passage 170 is part of a greater region 172, situated within portions of the inflated region to facilitate the flow of inflation gas from any inflatable region reacted upon by a vehicle occupant.

Figure 8 illustrates an alternate airbag 30a. This airbag also includes two Inflatable regions 32,34 and an uninflatable region 36 as well as a plurality of restrictions extending peripheral into respective inflatable regions.

The lateral borders 46a, 46b of airbag 30a are more noticeably curved than in the airbag 30. Airbag 30 shows the use of a single inlet 35, which is communicated to a source of inflation gas (not shown). The inflated region 36 is configured to form a narrow passage 180, which assists in communicating inflation gas from the inlet to each of the inflatable regions.

Alternatively, a distribution tube 182 made of metal, plastic or fabric can be inserted within the inlet and communicated to the inflator (not shown) to distribute the gases to the inflatable regions 32,34. The rear inflatable region 34 can be secured to an adjacent vehicle pillar by a panel 56 in the manner described above or by a thin strap or cord 56a.

Figure 9 shows an airbag 30 with a single inflatable region 32. The inflatable region 32 is positioned in front of an adjacent vehicle window 216.

The airbag includes a plurality of tabs 80 to mount the bag near the roof rail of the vehicle. The inflatable region 32 is in part defined by a plurality of restrictions, seams or joints generally shown as numerals 120,124, 126.

Each of the restrictions 120,124, 126 generally extends away from the periphery of the inflatable region 32 and extends toward the center of the inflatable regions 32 in the manner shown in the earlier figures. The restrictions shown in Figure 9 are more bulbous in shape than those shown in Figure 2. The restrictions of Figure 9 include wider and shorter stems 140 and relatively large heads 142. An advantage of this type of restriction, seam or joint 120,124, 126 is lower stress.

Figure 10 is a cross-sectional view of an airbag 30, folded and mounted to the vehicle proximate the roof rail 220. The generally planar airbag 30 has been folded into a number of accordion pleats 190. Each of the pleats extends from the front end to the rear end of the airbag. After the airbag has been folded it resembles a thin cylinder having a small D/L (folded diameter to length) ratio. For example, the diameter of the folded airbag may be about 38 mm to about 76 mm. The folded airbag 30 can be placed in a long, thin, tearable, flexible fabric or flexible plastic casing 192. The tabs 80 of the airbag extend through the opening in the casing 192. The casing and folded airbag are protectively enclosed in a clamshell housing 194. The housing 194, the casing 192 and the airbag 30 are secured proximate the roof rail 20 by the fasteners 90, each received through a corresponding tab 80. As the airbag 30 inflates with gas it expands, bursting the casing and opening the housing 194. The direction of opening of the housing 194 is shown by arrow 196. The housing 194 pushes away the fascia 198, which normally hides the airbag, permitting the airbag to expand and become situated along a side of the passenger compartment.