Airbag inflation-controlling member

Claim 2

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forced during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection including means for remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and so that said bag assumes an initial shape during initial stages of the inflation process and for extending said inflation-controlling member from said initial length to an intermediate length greater than said initial length so that said bag assumes an intermediate shape during intermediate stages of the inflation process; and said stretchable section including means for stretching said inflation-controlling member from said intermediate length to a final length greater than said intermediate length so that said bag assumes a final shape.

Claim 3

An airbag as set forth in claim 1 wherein said initial shape of said bag is a double-humped shape and wherein said final shape of said bag is roughly cylindrical.

Claim 4

An airbag as set forth in claim 1 wherein said releasable connection is of a strength which: withstands said initial forces and thus remains intact during initial stages of the inflation process thereby allowing said inflation-controlling member to extend to said initial length, and is overcome by said intermediate forces and thus releases during intermediate stages of the inflation process thereby allowing said inflation-controlling member to extend to said intermediate length.

Claim 5

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process so that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; and said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said releasable connection being of a strength which withstands said initial forces and thus remains intact during initial stages of the inflation process thereby allowing said inflation-controlling member to extend to said initial length, and which is overcome by said intermediate forces and thus releases during intermediate stages of the inflation process thereby allowing said inflation-controlling member to extend to said intermediate length; and said stretchable section being unaffected by said initial and intermediate forces and having elongation properties causing it to be elongated by the final forces thereby allowing said inflation-controlling member to extend from said intermediate length to said final length during the final stages of the inflation process.

Claim 6

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process so that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; and said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said releasable connection being of a strength which withstands said initial forces and thus remains intact during initial stages of the inflation process thereby allowing said inflation-controlling member to extend to said initial length, and which is overcome by said intermediate forces and thus releases during intermediate stages of the inflation process thereby allowing said inflation-controlling member to extend to said intermediate length; and said stretchable section being unaffected by said initial and intermediate forces and having elongation properties causing it to be elongated by the final forces thereby allowing said inflation-controlling member to extend from said intermediate length to said final length during the final stages of the inflation process.

Claim 7

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process of that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said inflation-controlling member being of a three-piece construction and comprising a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece, said central piece including said stretchable section.

Claim 8

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process of that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said inflation-controlling member being of a three-piece construction and comprising a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece, said central piece including said stretchable section.

Claim 9

An airbag as set forth in claim 1 wherein: said bag includes a mouth portion defining an inflation fluid inlet communicating with said chamber; said chamber-defining portions of said bag include an occupant-contacting portion which is positioned to contact an in-position vehicle occupant when said bag assumes said final shape; and said inflation-controlling member extends across said chamber from said mouth portion to said occupant-contacting portion.

Claim 10

An airbag as set forth in claim 6 wherein said occupant-contacting portion is located on a front region of said bag, approximately opposite said fluid inlet.

Claim 11

An airbag as set forth in claim 7 wherein said inflation-controlling member has a first end attached to said mouth portion and a second end attached to said occupant-contacting portion, said releasable connection and said stretchable section being located intermediate said first and second ends.

Claim 12

An airbag as set forth in claim 1 wherein said intermediate length is at least three times great as said initial length.

Claim 13

An airbag as set forth in claim 9 wherein said intermediate length is approximately five times as great as said initial length.

Claim 14

An airbag as set forth in claim 1 wherein said final length is at least ten percent longer than said intermediate length.

Claim 15

An airbag as set forth in claim 11 wherein said final length is twenty-five to thirty-six percent longer than said intermediate length.

Claim 16

An airbag as set forth in claim 1 wherein said intermediate length is at least three times great as said initial length and wherein said final length is at least ten percent longer than said intermediate length.

Claim 17

An airbag as set forth in claim 13 wherein said intermediate length is approximately five times as great as said initial length and wherein said final length is twenty-five to thirty-six percent longer than said intermediate length.

Claim 18

An airbag as set forth in claim 1 wherein said initial length is approximately 96 millimeters; said intermediate length is approximately 488 millimeters; and said final length is approximately 614-664 millimeters.

Claim 19

An airbag as set forth in claim 1 wherein said stretchable section has elongation properties causing it to elongate 50% to 70% when subjected to said final forces.

Claim 20

An airbag as set forth in claim 1 wherein said inflation-controlling member comprises a tether having a first end attached to said bag and a second end also attached to said bag, said releasable connection and said stretchable section being positioned on said tether intermediate said first and second ends.

Claim 21

An airbag as set forth in claim 17 wherein: said bag includes a mouth portion defining an inflation fluid inlet communicating with said chamber; said chamber-defining portions of said bag include an occupant-contacting portion which is positioned to contact an in-position vehicle occupant when said bag assumes said final shape; and said first end of said tether is attached to said mouth portion of said bag and said second end of said tether is attached to said occupant-contacting portion.

Claim 22

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process so that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said inflation-controlling member comprising a tether having a first end attached to said bag and a second end also attached to said bag, said releasable connection and said stretchable section being positioned on said tether intermediate said first and second ends; said bag including a mouth portion defining an inflation fluid inlet communicating with said chamber; said chamber-defining portions of said bag including an occupant-contacting portion which is positioned to contact an in-position vehicle occupant when said bag assumes said final shape; said first end of said tether being attached to said mouth portion of said bag and said second end of said tether being attached to said occupant-contacting portion; said tether being of a three-piece construction and comprising a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece; said first and second end pieces including said first and second ends of said tether, respectively.

Claim 23

A vehicle airbag comprising an inflatable bag and an inflation-controlling member which is coupled to said bag; said bag including chamber-defining portions defining a chamber which is filled with inflation fluid to inflate said airbag during an inflation process, said bag being subjected to initial forces during initial stages of the inflation process, intermediate forces during intermediate stages of the inflation process, and final forces during final stages of the inflation process; said inflation-controlling member extending through said chamber during the inflation process and controlling the shape of said bag; said inflation-controlling member including a releasable connection and a stretchable section; said releasable connection remaining intact during the initial stages of the inflation process so that said inflation-controlling member extends to an initial length and said bag assumes an initial shape; said releasable connection releasing during intermediate stages of the inflation process so that said inflation-controlling member extends from said initial length to an intermediate length greater than said initial length and said bag assumes an intermediate shape; said stretchable section stretching during final stages of the inflation process so that said inflation-controlling member extends from said intermediate length to a final length greater than said intermediate length and said bag assumes a final shape; said inflation-controlling member comprising a tether having a first end attached to said bag and a second end also attached to said bag, said releasable connection and said stretchable section being positioned on said tether intermediate said first and second ends; said bag including a mouth portion defining an inflation fluid inlet communicating with said chamber; said chamber-defining portions of said bag including an occupant-contacting portion which is positioned to contact an in-position vehicle occupant when said bag assumes said final shape; said first end of said tether being attached to said mouth portion of said bag and said second end of said tether being attached to said occupant-contacting portion; said tether being of a three-piece construction and comprising a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece; said first and second end pieces including said first and second ends of said tether, respectively.

Claim 24

An airbag as set forth in claim 19 wherein said releasable connection joins intermediate portions of said first and second end pieces together and wherein said central piece comprises said stretchable section of said inflation-controlling member.

Claim 25

An airbag as set forth in claim 20 wherein said releasable connection comprises break-away stitching.

Claim 26

An airbag as set forth in claim 20 wherein said central section is made of a material having a 45° weave pattern.

Claim 27

An airbag as set forth in claim 22 wherein said material is 840 denier nylon coated on one surface.

Claim 28

An airbag as set forth in claim 20 wherein said first and second end pieces are made of the same material as said central section and have a 90° weave pattern.

Claim 29

An airbag as set forth in claim 24 wherein said material is 840 denier nylon coated on one surface.

Claim 30

An airbag as set forth in claim 20 wherein said end pieces and said central piece are each rectangular in shape and each approximately 76 millimeters wide.

Claim 31

An airbag as set forth in claim 26 wherein said end pieces are each approximately 118 millimeters long and wherein said central piece is approximately 144 millimeters long.

Claim 32

An airbag as set forth in claim 21 wherein said break-away stitch pattern consist essentially of a stitch line having twenty stitches formed from 69 nylon thread and having an approximately 10 stitch/inch density.

Claim 33

An airbag as set forth in claim 28 wherein said stitch line has a span which is approximately 2/3 the width of one of said end pieces.

Claim 34

An airbag as set forth in claim 29 wherein said stitch line is centrally located on said end pieces.

Claim 35

An airbag as set forth in claim 30 wherein said stitch line has a span approximately equal to 51 millimeters and wherein said stitch line is located approximately 94 millimeters from either end of said end pieces.

Claim 36

An airbag inflation-controlling member for controlling the shape of an inflatable bag and absorbing forces imposed on the bag during an inflation process; said inflation-controlling member comprising a three-piece tether and means for coupling said tether to the bag; said tether including a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece; said tether also including a releasable connection and a stretchable section, said stretchable section being incorporated into said central piece; said releasable connection, when intact, allowing the tether to extend to an initial length, and, when released, allowing the tether to extend from said initial length to an intermediate length greater than said initial length; and said stretchable section allowing the tether to extend from the intermediate length to a final length greater than said intermediate length.

Claim 37

An airbag inflation-controlling member for controlling the shape of an inflatable bag and absorbing forces imposed on the bag during an inflation process; said inflation-controlling member comprising a three-piece tether and means for coupling said tether to the bag; said tether including a first end piece, a second end piece, and a central piece joining said first end piece to said second end piece; said tether also including a releasable connection and a stretchable section, said stretchable section being incorporated into said central piece; said releasable connection, when intact, allowing the tether to extend to an initial length, and, when released, allowing the tether to extend from said initial length to an intermediate length greater than said initial length; and said stretchable section allowing the tether to extend from the intermediate length to a final length greater than said intermediate length.

Claim 38

An inflation-controlling member as set forth in claim 32 wherein said intermediate length is at least three times great as said initial length.

Claim 39

An inflation-controlling member as set forth in claim 33 wherein said intermediate length is approximately five times as great as said initial length.

Claim 40

An inflation-controlling member as set forth in claim 32 wherein said final length is at least ten percent longer than said intermediate length.

Claim 41

An inflation-controlling member as set forth in claim 35 wherein said final length is twenty-five to thirty-six percent longer than said intermediate length.

Claim 42

An inflation-controlling member as set forth in claim 32 wherein said intermediate length is at least three times great as said initial length and wherein said final length is at least ten percent longer than said intermediate length.

Claim 43

An inflation-controlling member as set forth in claim 37 wherein said intermediate length is approximately five times as great as said initial length and wherein said final length is twenty-five to thirty-six percent longer than said intermediate length.

Claim 44

An inflation-controlling member as set forth in claim 32 wherein said initial length is approximately 96 millimeters, said intermediate length is approximately 488 millimeters, and said final length is approximately 614-664 millimeters.

Claim 45

An inflation-controlling member as set forth in claim 32 wherein said releasable connection comprises break-away stitching.

Claim 46

An inflation-controlling member as set forth in claim 32 wherein said central section is made of a material having a 45° weave pattern.

Claim 47

An inflation-controlling member as set forth in claim 41 wherein said material is 840 denier nylon coated on one surface.

Claim 48

An inflation-controlling member as set forth in claim 32 wherein said first and second end pieces are made of the same material as said central section and have a 90° weave pattern.

Claim 49

An inflation-controlling member as set forth in claim 43 wherein said material is 840 denier nylon coated on one surface.

Claim 50

An inflation-controlling member as set forth in claim 32 wherein said stretchable section has elongation properties causing it to elongate 50% to 70% when subjected to said final forces.

Claim 51

An inflation-controlling member as set forth in claim 32 wherein said end pieces and said central piece are each rectangular in shape and each approximately 76 millimeters wide.

Claim 52

An inflation-controlling member as set forth in claim 46 wherein said end pieces are each approximately 118 millimeters long and wherein said central piece is approximately 144 millimeters long.

Claim 53

An inflation-controlling member as set forth in claim 40 wherein said break-away stitch pattern consists essentially of a stitch line having twenty stitches formed from 69 nylon thread and having an approximately 10 stitch/inch density.

Claim 54

An inflation-controlling member as set forth in claim 48 wherein said stitch line has a span which is approximately 2/3 the width of one of said end pieces.

Claim 55

An inflation-controlling member as set forth in claim 49 wherein said stitch line is centrally located on said end pieces.

Claim 56

An inflation-controlling member as set forth in claim 50 wherein said stitch line has a span approximately equal to 51 millimeters and wherein said stitch line is located approximately 94 millimeters from either end of said end pieces.