Abstrict An integrated headliner and passive occupant restraint system and
a method of manufacturing the integrated headliner and passive occupant
restraint system and headliner is provided. The system includes
a headliner, an inflatable restraint air curtain and a gas generator.
The headliner is mounted inside a vehicle and across the interior
roof of the vehicle. The headliner may include a plurality of layers
comprised of PET Batt material or the like. The headliner insulates
the vehicle from outside sound and outside temperature. The inflatable
restraint curtain is disposed within the plurality of headliner
layers, the inflatable restraint curtain operative to cushion a
vehicle occupant's head and torso during a side impact collision.
Furthermore, a gas generator is in fluid communication with the
inflatable restraint curtain. The gas generator generates gas in
response to the signal generated by the plurality of sensors. The
generated gas inflates the curtain causing the curtain to expand
and tear the seam between the layers of the headliner and to cover
the window of the vehicle.
Claims What is claimed is:
1. An integrated passive occupant restraint system comprising:
a headliner mounted inside a vehicle and across the interior roof
of the vehicle, the headliner including a plurality of separate
layers with edges of said layers being overlaid along an outer periphery
of the headliner, the headliner operative to insulate the vehicle
from outside sound and outside temperature;
an inflatable restraint curtain compression molded to a compressed
position within the plurality of layers, the inflatable restraint
curtain operative to cushion a vehicle occupant's head and torso
during a side impact collision;
a plurality of sensors located at different points of the vehicle,
the plurality of sensors operative to detect a collision and to
generate a corresponding signal; and
a gas generator in fluid communication with the inflatable restraint
curtain, the gas generator generating gas in response to the signal
generated by the plurality of sensors, such that the generated gas
inflates the curtain causing the curtain to separate said edges
for deployment therebetween to cover the window of the vehicle.
2. The integrated passive occupant restraint system recited in
claim 1, wherein the inflatable restraint curtain having a first
end and a second end extending beyond the headliner, the inflatable
restraint curtain includes at least two mounting points, the first
mounting point being located at the first end and the second mounting
point being located at the second end.
3. The integrated passive occupant restraint system recited in
claim 1, wherein the headliner is comprised of polyethylene terephthalate
Batt materials.
4. The integrated passive occupant restraint system recited in
claim 1, wherein the air bag on inflation extends downward and toward
the floor of the vehicle.
5. An integrated passive occupant restraint system comprising:
a headliner mounted inside a vehicle and across the interior roof
of the vehicle, the headliner including a plurality of separate
layers with edges of said layers being overlaid and arranged coextensively
along an outer periphery of the headliner, the headliner operative
to insulate the vehicle from outside sound and outside temperature;
an inflatable restraint curtain compression molded to a compressed
position within the plurality of layers, the inflatable restraint
curtain operative to cushion a vehicle occupant's head and torso
during a side impact collision; and
a gas generator in fluid communication with the inflatable restraint
curtain, the gas generator generating gas to inflate the inflatable
restraint curtain causing the inflatable restraint curtain to deploy
between said edges to cover the window of the vehicle.
6. The integrated passive occupant restraint system recited in
claim 5, wherein the inflatable restraint curtain having a first
end and a second end extending beyond the headliner, the inflatable
restraint curtain includes at least two mounting points, the first
mounting point being located at the first end and the second mounting
point being located at the second end.
7. The integrated passive occupant restraint system recited in
claim 5, wherein the headliner is comprised of polyethylene terephthalate
Batt materials.
8. The integrated passive occupant restraint system recited in
claim 5, wherein the air bag on inflation extends downward and toward
the floor of the vehicle.
9. A method of manufacturing an integrated vehicle headliner and
air curtain assembly comprising:
providing a plurality of separately overlaid headliner layers arranged
with terraced edges proximate a side portion of the interior of
the vehicle;
positioning an inflatable air curtain between said plurality of
layers; and
compression molding the plurality of layers to form a headliner
assembly with the air curtain tightly compressed between said layers
proximate the terraced edges to minimize packaging requirements.
10. The method recited in claim 9 wherein the step of providing
a plurality of headliner layers includes providing a plurality of
polyethylene terephthalate Batt material layers. Description TECHNICAL FIELD
This invention relates to a side air curtain and inflator overhead
system and to a method of manufacturing thereof.
BACKGROUND ART
Automotive manufacturers have invested significant resources toward
the development of safety devices. These devices include active
restraint systems such as seat belts and passive restraint systems
such as air bags. Air bags are well known in the art and are frequently
implemented/incorporated into vehicles. Generally, air bag systems
include one or more air bags which are stored and packaged in a
folded or deflated condition in storage areas within the passenger
compartment of the motor vehicle. The air bag systems include sensors
located at various points in the vehicle. Upon impact, the sensors
are triggered thereby sending a signal to a gas generator or ignitor.
The gas generator or ignitor is connected/linked to the air bag.
The gas generator operates to inflate the air bag when it receives
a signal from the sensors.
As the air bag is inflated, the air bag breaks through its storage
compartment and then acts to cushion the vehicle occupant against
impact with the interior of the motor vehicle.
It is well known in the art to mount air bags in the front dashboard
of a motor vehicle on the front passenger side or in the steering
wheel of a motor vehicle in order to protect a driver. Although
known in the art and less commonly implemented, side mounted air
bags may be employed in a motor vehicle. Side mounted air bags are
generally mounted directly onto the roof of the vehicle where the
side mounted air bag is a curtain which protects the occupant from
colliding against the A-Pillar, B-Pillar, and/or windows of the
motor vehicle. Upon impact, the side mounted air curtain air bag
inflates and bends the headliner edge downward so that the air curtain
may protect the occupant from the window and pillars of the motor
vehicle. Although this air bag has many benefits, the space limitations
in the interior of a motor vehicle have proven it difficult to incorporate
this type of air bag into a motor vehicle. For example, upon impact
the side air curtain must be securely anchored to the motor vehicle
to insure that it is properly positioned between the occupant and
the vehicle frame/windows. In an attempt to meet this objective,
prior art systems generally anchored at several points along the
curtain or at each end of the air curtain to the roof of the motor
vehicle. U.S. Pat. No. 5,588,672 issued to Karlow et al. discloses
the curtain-style air bag and a typical mounting arrangement where
the air bag curtain is mounted at each end of the curtain. Karlow
further mounts one end of the curtain to a moveable mounting point
to guide the curtain down the vehicle as it is inflated. Other systems
may include a tether between the air bag curtain and the roof to
properly guide the curtain down the motor vehicle.
However, as part of the manufacturing process, a substantial amount
of time and labor resources are used to mount the air bags to the
motor vehicle and then assemble the components surrounding the vehicle.
For example in U.S. Pat. No. 5,470,103 issued to Vaillancourt, a
motor vehicle head impact air bag system is provided. The Vaillancourt
reference describes an air bag which deploys downward from impacting
with the upper interior portions of the vehicle. The air bag is
hidden in the ceiling of the vehicle behind panels in a vinyl cover.
The panels open by the inflation of the air bag to allow its downward
deployment. The panels are defined by a tear seam and a living hinge
formed in the vinyl cover.
With respect to the side curtain air bag, this type of air bag,
as mentioned before, is generally mounted directly to the roof of
the motor vehicle. Then, the next manufacturing step requires the
attachment of the headliner to the motor vehicle. These separate
manufacturing steps require automobile assemblers to invest more
time, packaging costs, and labor costs than is necessary to produce
a vehicle.
Consequently, a need has developed for a side impact head restraint
system which is integrated with a headliner of an automobile thereby
reducing manufacture time and manufacture errors while ensuring
an effective and reliable safety restraint system.
DISCLOSURE OF INVENTION
It is a principle object of this invention to provide an integrated
passive occupant restraint system and headliner which may be installed/incorporated
into a motor vehicle in one step.
It is another object of this invention to reduce the time of assembling
a motor vehicle and the cost of assembling a motor vehicle.
It is yet another object of the present invention to provide a
side impact head restraint system which meets minimal packing space
requirements.
It is still another object of the present invention to provide
a method for manufacturing an air bag curtain which is integrated
with a headliner.
In carrying out the above objects and other objects and features,
an integrated passive occupant restraint system and headliner is
provided. The integrated headliner and passive occupant restraint
system which includes a headliner, an inflatable restraint curtain,
and a gas generator. The headliner is generally mounted inside a
vehicle and across the interior roof of the vehicle. The headliner
may include a plurality of PET (Polyethylene Terephthalate) Batt
layers or other material such as foam. The headliner insulates the
vehicle from outside sound and outside temperature. The inflatable
restraint curtain is disposed within one or more of the headliner
layers. Once inflated, the inflatable restraint curtain serves to
cushion a vehicle occupant's head and torso during a side impact
collision. The inflatable restraint curtain extends beyond the headliner
and is mounted to the vehicle at least two points. The first mounting
point is located at a first end of the curtain and the second mounting
point is located at the second end of the curtain. The inflatable
air curtain is triggered by one or more sensors which are located
at different points in the vehicle. The sensors detect a collision
to generate a corresponding signal.
More particularly, the headliner may be comprised of one or more
PET Batt layers where the side air curtain is embedded between the
PET Batt layers and the layers are joined through compression molding.
Still more particularly, the sensors and the inflatable air curtain
cooperate with a gas generator which is in fluid communication with
the inflatable restraint curtain. The gas generator generates gas
in response to a signal generated by the plurality of sensors, the
generated gas inflates the curtain causing the curtain to deploy
thereby tearing the seam between the headliner layers and eventually
covering the window of the vehicle.
A method of manufacturing an integrated vehicle headliner and air
curtain is also provided. The method includes: providing a plurality
of layers of headliner material; positioning an inflatable air curtain
between said plurality of layers; and compression molding the plurality
of layers to form a headliner assembly with the air curtain compressed
between said layers.
As those skilled in the art will recognize, the specific embodiment
of this invention can vary depending upon the specific requirements
of the air curtain assembly and the headliner. Although the particular
size, shape and form of the air bag curtain and headliner will vary,
all embodiments utilize the elements of this invention.
The above objects, and other objects, features and advantages of
the present invention are more readily understood from a review
of the attached drawings and the accompanying specification and
claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a perspective view of the integrated headliner
and air bag curtain installed in a motor vehicle;
FIG. 2 is a cross-sectional view of the folded air bag curtain
embedded in the headliner; and
FIG. 3 is a front view of the driver side of the vehicle in FIG.
1 with the air bag deployed.
FIG. 4 is a flow chart which illustrates the method of manufacturing
the integrated headliner and airbag curtain.
BEST MODE FOR CARRYING OUT THE INVENTION
With reference to FIG. 1 of the drawings, the integrated passive
occupant restraint system 10 is illustrated as installed in a motor
vehicle 28. As shown, the headliner 12 may include several layers
14 of material. The layers of material may be comprised of PET Batt
materials or other material such as foam or cardboard. The inflatable
air curtain 16 may positioned between the several layers of material.
The present invention may further includes a gas generator 18 which
is in communication with one or more sensors 20. The sensors 20
may come in a variety of forms but all forms of the sensors 20 serve
the purpose of detecting a collision and transmitting a signal to
the gas generator 28 such that the gas generator 18 inflates the
side air curtain 16. The gas generator 18 may be connected to the
inflatable side air curtain 16 through a hose.
The air bag curtain 16 includes a first end 24 and a second end
26 which extend beyond the headliner 12. The inflatable side curtain
16 may be mounted to the vehicle 28 through its connection to the
gas generator 18 at its first end 24 and a tether 21 at its second
end 26. The gas generator 18 may be directly mounted to the interior
roof 30 of the vehicle 28. The gas generator 18 may be further connected
to the inflatable side air curtain 16 through a hose 22. The inflatable
side curtain 16 may also be connected at its second end 26 through
a tether2l. In an alternative arrangement, the present invention
may include tethers 21 which directly fasten the air curtain 16
onto the interior roof 30, A-Pillar, and/or the C-Pillar 32 of the
vehicle 28. In attaching the air curtain 16 to the interior roof
30, the air curtain may be attached through grab handles, coat hooks,
or visor mounts.
As the air curtain 16 expands and moves down the interior of the
vehicle 28, the tether 21 prevents the air curtain 16 from moving
toward the roof 30 or toward the interior of the vehicle. As those
skilled in the art will recognize, the mounting points to the air
curtain 16 may be positioned in a variety of places.
With reference to FIG. 2 of the drawings, a cross sectional view
of the vehicle headliner and air curtain assembly 10 is shown. The
inflatable side air curtain 16 is shown in its storage mode where
it is folded or collapsed between the layers 14 of the headliner
12. In another embodiment (not shown), the inflatable side air curtain
may be embedded in a single layer of the headliner. The integrated
side air curtain and inflator overhead system operates to cushion
the vehicle occupant against impacting the interior of the vehicle
by inflating the air curtain 16 upon collision. Upon collision,
the sensors (not shown in FIG. 2) detect the collision and transmit
a signal to the gas generator (not shown in FIG. 2). In turn, the
gas generator 18 inflates the air curtain 16. The air curtain 16
expands and breaks the seam between the layers 14 of the headliner
12. The air curtain 16, as it expands, moves down the interior of
the vehicle to protect the vehicle occupant from impacting the interior
of the vehicle.
The integrated system in its deployed condition is further illustrated
in FIG. 3. As shown, the headliner 12 is torn along the seam of
the layers 14 where the air curtain 16 rested as the air curtain
16 expanded. The air curtain 16 extends down the vehicle so that
it may be positioned between the vehicle occupant and the side portion
of the vehicle's interior.
Referring now to FIG. 4, the method of manufacturing the integrated
side air curtain and inflator overhead system is illustrated in
a flow chart format. First, a plurality of layers of headliner material
is provided 38. The headliner material is preferably but not necessarily
comprised of PET Batt material. In the alternative, the headliner
material may be comprised of foam, cardboard or the like. Second,
the inflatable air curtain may be positioned 40 between the layers
of the headliner. Third, the layers of material and the inflatable
air curtain are compression molded 42 to form a headliner assembly
with the air curtain compressed between the layers of the headliner
material.
In yet another embodiment, the headliner may be comprised of a
single layer where the inflatable air curtain may be embedded within
the single layer. The overhead system may be formed by positioning
the inflatable air curtain in a mold and pouring the material for
the headliner around the air curtain. The combined materials are
then heat treated to form the integrated overhead system. Upon inflation
the air curtain is capable of breaking through the headliner layer
to move down the interior of the vehicle thereby preventing the
occupant from impacting the interior of the vehicle.
While embodiments of the invention have been illustrated and described,
it is not intended that these embodiments illustrate and describe
all possible forms of the invention. Rather, the words used in the
specification are words of description rather than limitation, and
it is understood that various changes may be made without departing
from the spirit and scope of the invention. |