Vehicle restraint system with inflation control

Claim 1

A side impact restraint system for protecting an occupant of a vehicle comprising: an inflatable cushion (100) expandable from a compact pre-inflated condition to an inflated condition, the cushion including a first chamber (101a) and a second chamber (102a) and separator means (110) for separating the cushion into the first and second chambers and for controlling the flow of inflation gas therebetween; an inflator support member (120) receivable within the cushion, the inflator support member including mounting means for mounting the support member to a mounting member of the vehicle; an inflator (125) for providing inflation gas directly to at least the first chamber of the cushion, the inflator mounted to the inflator support member; the separator means including a separator panel and a safety flap attached to the separator panel, wherein portions of the separator panel and the safety flap are movable relative to one another as the cushion inflates to create a variable aperture (104); the separator panel includes a first portion secured to the cushion thus dividing the cushion into the first and second chambers, the separator panel additionally includes a first aperture (111) and a first end (113) secured to the inflator support member; the safety flap (130) includes a second aperture (131) which is initially maintained registered to the first aperture, a first end portion of the safety flap on one side of the second aperture being formed into an expansion pleat or loop (136), an end of the expansion pleat remote from the second aperture is secured to the separator panel by a permanent connection, the safety flap is also secured to the separator panel by at least one breakable connection which is broken as the cushion inflates, an opposite end of the safety panel being secured to the inflator support member without any significant slack therein; wherein the separator panel, between the location of the breakable connection and its first end, which is secured to the inflator support member, is formed with slack therein; wherein upon inflation of the cushion, the separator panel is tensioned causing the breakable connection to break thereby permitting the expansion pleat to expand permitting portions of the safety flap adjacent the second aperture to move relative to the first aperture obscuring portions of the first aperture (111) thereby creating the variable aperture (104).