Vehicle door with pre-deployed air bag

Claim 2

A vehicle door comprising: an inner panel; an outer panel joined to said inner panel; a door trim substrate mounted on said inner panel; a door trim cover mounted on said door trim substrate to form a space therebetween; and generally pre-deployed air bag means extending vertically and longitudinally and disposed in the space between said door trim substrate and said door trim cover for inflation upon an impact on said vehicle door by another object, said air bag means causing said door trim cover to detach said door trim substrate upon inflation.

Claim 3

A vehicle door as set forth in claim 1 wherein said air bag means comprises at least one air bag having inner and outer edges and upper and lower edges interconnecting said inner and outer edges.

Claim 4

A vehicle door as set forth in claim 2 including means for securing said inner edges of said air bag to said door trim substrate.

Claim 5

A vehicle door as set forth in claim 3 including means for securing said outer edges of said air bag to said door trim cover.

Claim 6

A vehicle door as set forth in claim 2 wherein said upper and lower edges are folded in an accordion manner.

Claim 7

A vehicle door as set forth in claim 1 including means for removably securing said door trim cover to said door trim substrate.

Claim 8

A vehicle door as set forth in claim 6 wherein said securing means comprises a plurality of interlocking strips secured to said door trim substrate and said door trim cover and cooperating together to removably secure said door trim cover to said door trim substrate.

Claim 9

A vehicle door as set forth in claim 1 including means for controlling inflation of said air bag means.

Claim 10

A vehicle door as set forth in claim 8 wherein said controlling means comprises at least one tether interconnecting said door trim substrate and said door trim cover.

Claim 11

A vehicle door as set forth in claim 8 wherein said controlling means comprises at least one tether interconnecting said inner and outer edges of said air bag.

Claim 12

A vehicle door as set forth in claim 1 wherein said air bag means includes at least one-sensor for sensing an impact on said vehicle door.

Claim 13

A vehicle door as set forth in claim 11 wherein said air bag means includes at least one inflator connected to said sensor to inflate said air bag means upon an impact sensed by said sensor.

Claim 14

A vehicle door as set forth in claim 12 including at least one duct connected to said inflator and said air bag means and orientated to expel gas upwardly toward the occupant.

Claim 15

A vehicle door comprising: an inner panel; an outer panel joined to said inner panel; and an air bag assembly mounted on said inner panel and including a door trim substrate mounted on said inner panel, a door trim cover removably secured to said door trim substrate to form a space therebetween, and at least one air bag disposed in the space and having a partially extended position extending vertically and longitudinally along said vehicle door in an uninflated state and a fully extended position in an inflated state upon an impact on said vehicle door by another object, said at least one air bag causing said door trim cover to detach said door trim substrate upon inflation.

Claim 16

A vehicle door comprising: an inner panel; an outer panel joined to said inner panel; and an air bag assembly mounted on said inner panel and including a door trim substrate mounted on said inner panel, a door trim cover removably secured to said door trim substrate to form a space therebetween, and at least one air bag disposed in the space and having a partially extended position extending vertically and longitudinally along said vehicle door in an uninflated state and a fully extended position in an inflated state upon an impact on said vehicle door by another object, said at least one air bag causing said door trim cover to detach said door trim substrate upon inflation.

Claim 17

A vehicle door as set forth in claim 14 wherein said air bag has inner and outer edges and upper and lower edges interconnecting said inner and outer edges, said inner edges being secured to said door trim substrate.

Claim 18

A vehicle door as set forth in claim 15 including means for removably securing said door trim cover to said door trim substrate.

Claim 19

A vehicle door as set forth in claim 15 including means for controlling inflation of said air bag.

Claim 20

A vehicle door as set forth in claim 15 wherein said upper and lower edges are folded in an accordion manner.

Claim 21

A vehicle door comprising: an inner panel; an outer panel joined to said inner panel; a door trim substrate mounted on said inner panel; a door trim cover mounted on said door trim substrate to form a space therebetween; a generally pre-deployed air bag extending vertically and longitudinally and disposed in the space between said door trim substrate and said door trim cover, said air bag having inner and outer edges and upper and lower edges interconnecting said inner and outer edges, said inner edges of said air bag being secured to said door trim substrate; a plurality of interlocking strips secured to said door trim substrate and said door trim cover and cooperating together; at least one tether interconnecting said door trim substrate and said door trim cover for controlling inflation of said air bag; at least one sensor for sensing an impact on said vehicle door; at least one inflator connected to said sensor to inflate said air bag upon an impact sensed by said sensor; and at least one duct connected to said inflator and said air bag and oriented to expel gas upwardly toward the occupant, said air bag causing said door trim cover to detach said door trim substrate upon inflation.

Claim 22

A vehicle door comprising: an inner panel; an outer panel joined to said inner panel; a door trim substrate mounted on said inner panel; a door trim cover mounted on said door trim substrate to form a space therebetween; a generally pre-deployed air bag extending vertically and longitudinally and disposed in the space between said door trim substrate and said door trim cover, said air bag having inner and outer edges and upper and lower edges interconnecting said inner and outer edges, said inner edges of said air bag being secured to said door trim substrate; a plurality of interlocking strips secured to said door trim substrate and said door trim cover and cooperating together; at least one tether interconnecting said door trim substrate and said door trim cover for controlling inflation of said air bag; at least one sensor for sensing an impact on said vehicle door; at least one inflator connected to said sensor to inflate said air bag upon an impact sensed by said sensor; and at least one duct connected to said inflator and said air bag and oriented to expel gas upwardly toward the occupant, said air bag causing said door trim cover to detach said door trim substrate upon inflation.