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`PATENT NUMBER
`
`·,
`
`: \
`
`U.S. UTILITY Patent Application
`PATENT DATE
`,,-°i;i.~.-E.,
`' 8)
`c'.'.'1
`\__ V\
`
`SCANNED
`
`Q.A. ___ _
`
`MAR 18 2003
`
`APPLICATION NO.
`
`CONT/PRIOR
`
`UJ
`.J
`I-
`
`~ Ptf
`
`PT0-2040
`12/99
`
`ORIGIMAL
`
`l
`
`SUBCLASS
`CLASS
`735"
`280
`INTERNATIONAL CLJ\SSIFICATION
`21/32
`
`B (o 0 f(
`
`ISSUING CLASSIFICATION
`CROSS REFERENCE(S)
`
`CLASS
`70/
`
`SUBCLASS (ONE SUBCLASS PER BLOCK)
`L/5
`
`'
`
`,,,
`
`R rmat orawtoos QJ_shts) set
`DRAWINGS
`
`Sheets Drwg.
`
`3Lj
`
`Figs. Drwg.
`
`33
`
`(date)
`
`.
`
`··-
`
`Print Fig.
`
`I
`
`-
`
`(Date)
`
`D Continued on Issue Slip Inside File Jacket
`f -~3-0 I
`CLAIMS ALLOWED
`Print Claim for 6.G.
`I
`
`Total Claims
`
`NOTICE OF ALLOWANCE MAILED
`
`~,
`~1,1~
`/D--~~1Y)_~
`
`..
`
`,
`ISSUE FEE
`
`Amount Due
`
`(Assistant Examiner)
`'.
`AVAAHAMLERNER
`PRIMARV EXAMINER
`e)foi
`/4'/4w-t_
`~C(O
`'/ZUJi.-
`J ( ' J '
`ISSUE BATCH NUMBER
`/ C,~01,1/v,;- z;-9-t)~
`
`ds--~,-C)~
`[ZJ TERMINAL
`DISCLAIMER
`
`D The term of this patent
`subsequent to
`has been disclaimed.
`
`rzf' The term of this patent shall
`not extend beyond ze expiration date
`of U.S Patent. No .. , ti 2o/, ~2 ~'
`
`l
`
`tJ The terminal _months of
`this patent have been disclaimed.
`
`~ary Examiner)
`
`(Date)
`
`(Legal Instruments Examiner)
`
`(Date)
`
`WARNING:
`The information disclosed herein may be restricted. Unauthorized disclosure may be prohibited by the United States Code Title 35, Sections 122, 181 and 368.
`Possession outside the U.S. Patent & Trademark Office is restricted to authorized employees and contractors only.
`
`Form PT0-436A
`(Rev. 6/99)
`
`FILED WITH: D DISK (CRF) D FICHE D CD-ROM
`
`(Attached in pocket on right inside flap)
`
`~1ts) set-:-___ _
`,
`'\.----
`
`IPR 2016-01794
`American Vehicular Sciences
`Exhibit 2024
`
`(FACE)
`
`1
`
`

`

`''
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`15. ________ _
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`37. _ ____ __ _ _
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`38. ___ ___ __ _
`
`39. ___ ___ __ _
`
`40. _ __ _ ______ _
`
`CONTENTS
`Date Received
`(Incl. C. of M.)
`or
`Date Mailed
`
`INITIALS .J../:z. f,)n;
`
`IL
`
`Date Received
`(Incl. C. of M.)
`or
`Date Mailed
`
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`- - - - - - - - - - - - - -
`63.
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`80.
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`41. ______ __ _ - - - - 82. _____ __ __ - - - -
`
`(LEFT OUTSIDE)
`
`2
`
`

`

`ISSUE SLIP STAPLE P REA (for i:i,,,iitpnal cross references)
`~--'---- -- ··- ----·----,-..-·-·· ·--·-- -
`!NI'"' ·'ts
`POSiTION
`. __ ,;_,-t---
`--- ---·--·------ -
`F~E DETERMINATION
`0.1.P.E. CLASSIFIER
`FORMALITY REVIEW
`RESPONSE FORMALITY REVIEW
`
`iJ NO.
`
`----------1
`
`DATE
`
`INDEX OF CLAIMS
`v ................................. Rejected
`N ................................. Non-elected
`I
`................................. Interference
`=
`................................. Allowed
`A ................................. Appeal
`(Through numeral) ... Canceled
`O ................................. Objected
`...................... ' ........... Restricted
`
`Claim
`
`Date
`
`·2 2
`3 3
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`5 5
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`1'1
`9
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`70
`71
`72
`73
`74
`75
`76
`77
`78
`79
`80
`81
`82
`83
`84
`85
`86
`87
`88
`89
`90
`91
`92
`93
`94
`95
`96
`97
`98
`99
`10(
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`Date
`
`Claim
`
`Date
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`119
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`h45
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`14E
`149
`15C
`
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`
`If more than 150 claims or 1 O actions
`staple additional sheet here
`
`(LEFT INSIDE)
`
`3
`
`

`

`I ,,
`
`SEARCHED
`
`SEARCH NOTES
`(INCLUDING SEARCH STRATEGY)
`
`Class
`Sub.
`WJ ?JS'
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`2,fz_
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`
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`· .~
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`
`PATENl'<ABfLICt\TION···sE~AL NO .. _________ _
`
`l])S. DEfARTMltNT OF COMMERCE
`B;\TENT AND TRi\DEMARK OFFICE
`~E RECORD ·SHEET
`
`01/30/2001 TLWll ooooo,tt.•5*&6 . 6'167tlO
`01 FC:201
`02 FC:203
`03 FC:202
`
`I
`PT0-1556
`(5/87)
`
`'U.S. GPO: 1999-459-082/19144
`
`5
`
`

`

`UNITED STATES PATENT AND ThADEMARK OFFICE
`
`,j !ml 11111111111 ~Ill llll Ill llllll l~l llll llll llllll I 1111
`Bib Data Sheet
`
`\
`
`Page 1 of 1
`
`COMMISSIONER FOR P/I.TE1'1TS
`UNITED ST/I.TES PATENT AND TRADEMARK OFFICE
`WASHINGlON, D.C. 20231
`www.uspto.gov
`
`CONFIRMATION NO 5056
`
`SERIAL NUMBER
`09/767,020
`
`FILING DATE
`01/23/2001
`RULE
`
`CLASS
`340
`
`GROUP ART UNIT
`2623
`
`ATTORNEY
`DOCKET NO.
`ATL-:247
`
`APPLICANTS
`David S. Breed, Boonton ,:ownship, NJ;
`Wilbur E. DuVall, Kimberling City, MO;
`Wendell C. Johnson, Signal Hill, CA;
`William Thomas Sanders, Rockaway To2wship, NJ·
`
`** CONTINUING DATA*************************
`. THIS APPLICATION IS A CIP OF 09/073,.i03 05/06/1998 PAT 6,179,326
`WHICH IS A CIP OF 08/571,247 12/12/1995 PAT 5,772,238
`I AND A CIP OF 08/550,217 10/30/1995 ABN
`ci\10' ~ · IS A CIP OF 09/356,314 07/16/1999
`WHICH IS A CIP OF 08/947,66110/09/1997 ABN
`AND A CIP OF 09/137,918 08/20/1998 PAT 6,175,787
`. WHICH IS A CIP OF 08/476,077 06/07/1995 PAT 5,809,437
`AND CLAIMS BENEFIT OF 60/028,046 10/09/1996
`
`** FOREIGN APPLICATIONS ******************** ~
`
`IF REQUIRED, FOREIGN FILING LICENSE GRANTED .... SMALL ENTITY ....
`** 04/26/2001
`/
`CJ yrie·1""'71
`35 USC 119 (a-d) conditions CJ yes
`no CJ ty,et after
`
`Foreign Priority claimed
`
`met
`Verified and
`Acknowledged
`~DDRESS
`~2846
`
`Allowa ce
`
`Examiner's Sianature
`
`Initials
`
`STATE OR
`COUNTRY
`NJ
`
`SHEETS
`DRAWING
`34
`
`TOTAL
`CLAIMS
`59
`
`INDEPENDENT
`CLAIMS
`6
`
`il"ITLE
`
`~utomotive electronic safety network
`
`FILING FEE FEES: Authority has been given in Paper
`RECEIVED No. ____ to charge/credit DEPOSIT ACCOUNT
`826
`No.
`'
`for following:
`
`\ \
`
`/
`
`!CJ All Fees
`!CJ 1.16 Fees (Filing)
`[J 1.17 Fees ( Processing Ext. of
`time)
`
`l[J 1.18 Fees (Issue).
`l[J Other
`l[J Credit
`
`I
`I
`I
`
`6
`
`

`

`Page 1 of 1
`
`~----41Q,r"'-·
`
`W-r,gton. CIC 2Q231
`www .. uspto.gov
`
`CONFIRMATION NO. 5056
`
`CLASS
`280
`
`GROUP ART UNIT
`3618
`
`ATTORNEY
`DOCKET NO.
`ATl-247
`
`1 lllllll lllll lllll ll~I IIHIIIID IH 111111 IH IH 11111~110111111
`
`Bib Data Sheet
`
`SERIAL NUMBER
`09/767,020
`
`FILING DATE
`01/23/2001
`RULE
`
`APPLICANTS
`Qavid S. Breed, Boonton Township, NJ;
`Wilbur E. DuVall, Kimberling City, MO;
`Wendell C. Johnson, Signal Hill, CA;
`William Thomas Sanders, Rockaway Township, NJ;
`
`** CONTINUING DAT A *************************
`This application is a GIP of 09/073,403 05/06/1998 PAT 6,179,326
`which is a GIP of 08/571,247 12/12/1995 PAT 5,772,238
`and.is a GIP of 08/550,217 10/30/1995 ABN
`This application 09/767,020
`is a CIP of 09/356,314 07/16/1999 PAT 6,326,704
`which is a GIP of 08/947,661 10/09/1997 ABN
`and is a GIP of 09/137,918 08/20/1998 PAT 6,175,787
`which is a GIP of 08/476,077 06/07/1995 PAT 5,809,437
`and claims benefit of 60/028,046 10/09/1996
`
`** FOREIGN APPLICATIONS ********************
`
`IF REQUIRED, FOREIGN FILING LICENSE GRANTED** SMALL ENTITY**
`** 04/26/2001
`1./1.
`I r I
`yesr:z··
`yes L . .J no l~ Met after
`
`STATE OR
`COUNTRY
`NJ
`
`SHEETS
`DRAWING
`34
`
`TOTAL
`CLAIMS
`59
`
`INDEPENDENl
`CLAIMS
`·6
`
`Foreign Priority claimed
`35 use 119 (a-d) conditions
`met
`Verified and
`Acknowledaed
`ADDRESS
`~2846
`
`Allowance
`
`Examiner's Sianature
`
`Initials
`
`TITLE
`
`~UTOMOTIVE ELECTRONIC SAFETY NETWORK
`
`FILING FEE FEES: Authority has been given in Paper
`~ECEIVED No. ____ to charge/credit DEPOSIT ACCOUNT
`1144
`No. ____ for following:
`
`1
`
`I
`
`[JAIi Fees
`
`LJ 1.16 Fees ( Filing )
`l1
`. i 1. t:Z. Fee$i i,P,r,opessing Ext. of
`time) ·.
`"'


`jl'r'
`c ... J 1.18 Fees (Issue)
`I'·, L. : Other
`l~J Credit
`
`I r
`
`I
`
`7
`
`

`

`oi-23--oi
`
`A
`
`PTO/SB/05 (08-
`Approved for use through 10/31/2002. 0MB 0651-0,
`Please type a plus sign(+) inside this box ~ [!I
`U.S. Patent and Trademark Office; U.S. DEPARTMENT OF COMMER
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`
`UTILITY
`PATENT APPLICATION
`TRANSMITTAL
`
`Attorne Docket No. AT I - 2 4 7
`David S. · Breed
`First Inventor
`Title Automotive Electronic .••
`
`On/ for new non rovisional a
`
`/lcations under 37 CFR 1.53 b
`
`APPLICATION ELEMENTS
`
`1. or]
`2. [i]
`3.[i]
`
`Fee Transmittal Form (e.g., PTO/SB/17)
`(Suh mil an original and a d11plieate for fee proce.,.dng)
`Applicant claims small entity status.
`See 37 CFR 1.27.
`[Tota/ Pages ~ )
`Specification
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`- Descriptive title of the invention
`- Cross Reference to Related Applications
`- Statement Regarding Fed sponsored R & D
`- Reference to sequence listing, a table,
`or a computer program listing appendix
`- Background of the Invention
`- Brief Summary of the Invention
`- Brief Descriptfon of the Drawings (if filed)
`- Detailed Description
`- Claim(s)
`- Abstract of the Disclosure
`[ Total Sheets rn ]
`4. [!J Drawing(s) (35 U.S.C. 113)
`[ Total Pages rr:J3 ]
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`'~)_.,, '
`Other:
`., ... , ........................................ ..
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`16.o
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`_:,.
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`Assistant Commissioner for Patents
`ADDRESS TO: Box Patent Application
`Washln ton, DC 20231
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`Computer Program (Appendix)
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`12.K]
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`13.o
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`Signed statement attached deleting lnventor(s)
`named In the prior application, see 37 CFR
`1.63(d)(2) and 1.33(b).
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`Application Data Sheet. See 37 CFR 1. 76
`17. If a CONTINUING APPLICATION, check appropriate box, and supply the requisite information below and in a preliminary amendment,
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`For CONTINUATION OR DIVISIONAL APPS only: The entire disclosure of the prior appllcation, from which an oath or declaration is supplied under
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`18. CORRESPONDENCE ADDRESS
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`
`8
`
`

`

`· · - - - · - - - -
`
`.. ------~----~---
`
`FEE TRANSMITTAL
`for FY 2001
`
`Patent fees are subject to annual revision.
`
`TOTAL AMOUNT OF PAYMENT
`
`($)
`
`866
`
`lication Number
`A
`Filing Date
`
`First Named Inventor
`Examiner Name
`Group Art Unit
`Attorney Docl<et No.
`
`January 22, 2001
`David S. Breed
`
`ATI-247
`
`1v7
`1. lllo..J
`
`METHOD OF PAYMENT
`The Commissioner is hereby authorized to charge
`indicated fees and credit any overpayments to:
`
`f:o~s~: 5 0 - 0 2 6 6
`Number '.:::===============~
`I
`Deposit
`Account Automotive Tech. Int' 1
`Name
`.
`
`FEE CALCULATION continued
`3. ADDITIONAL FEES
`Large EntltySmall Entity
`Fee
`Fee Fee
`Fee
`Code ($) Code
`($)
`65 Surcharge - late filing fee or oath
`105 130 205
`
`Fee Description
`
`Fee Paid
`
`127
`
`50 227
`
`25 Surcharge - late provisional filing fee or
`cover sheet
`
`139 130 139 130 Non-English specification
`
`r
`147 2,520 147 2,520 For filing a request for ex parte reexaminatio
`112 920' 112 920' Requesting publication of SIR prior to
`Examiner action
`113 1,840' 113 1,840' Requesting p_ublication of SIR after
`Examiner action
`
`115 110
`
`215
`
`55
`
`Extension for reply within first month
`
`116 390
`117 890
`
`216 195
`217 445
`
`118 1,390
`
`218 695
`
`Extension for reply within second month
`
`Extension for reply within third month
`
`Exte_nsio,r
`for reply within fourth month
`1
`Exten~iop for reply within fifth month
`
`Notice of Appeal
`
`Filing a brief in support of an appeal
`
`228 945
`
`219 155
`
`220 155
`
`121 270
`138 1,510
`
`140 119
`
`221 135
`1381,510
`
`Request for oral hearing
`Petition to institute a public use proceeding
`
`240
`
`55
`
`Petition to revive - unavoidable
`
`:j~:i r
`,!
`
`2. D
`0
`
`Charge Any Additional Fee Required
`Under37CFR 1.16and 1.17
`_Applicant claims small entity status.
`·see 37 CFR 1.27
`Payment Enclosed:
`Check O Credit card D ~~;:{
`FEE CALCULATION
`1. BASIC FILING FEE
`Large Entity Small Entity
`Fee Description
`Fee Fee Fee Fee
`Code ($) Code ($)
`101 710
`201 355 Utility filing fee
`206 160 Design filing fee
`
`106 320
`
`107 490
`108 710
`
`114 150
`
`207 245 Plant filing fee
`208 355 Reissue filing fee
`75 Provisional filing fee
`
`214
`
`0 Other
`
`Fee Paid
`
`355
`
`128 1,890
`
`119 310
`
`120 310
`
`~
`
`SUBTOTAL (1) I($)
`2. EXTRA CLAIM FEES
`Fee from
`Extra Claims ~ Fee Paid
`=I 351 I
`~ -20"= ~ X
`Independent DJ -3"= CJ] x[]][J=I 120 I
`I
`
`Total Claims
`
`Claims
`Multiple Dependent
`
`c=J=I
`
`Large Entity Small Entity
`Fee Fee Fee Fee
`Code ($) Code ($)
`103
`18
`203
`9
`
`Fee Description
`
`Claims in excess of 20
`
`80
`102
`104 270
`
`202 40
`204 135
`
`109
`
`80
`
`209 40
`
`110
`
`18
`
`210
`
`9
`
`Independent claims in excess of 3
`
`Multiple dependent claim, if not paid
`
`•• Reissue independent claims
`over original patent
`
`"Reissue claims in excess of.20
`and over originalp ~a_te_n_t ___ --..
`
`SUBTOT AL (2) .
`
`I ($) 4 71
`
`"or n,:1mber previous/ paid, if realer; For Reissues, see above
`
`141 1,240
`142 1,240
`143 440
`
`241 620
`242 620
`243 220
`
`Petition to revive - unintentional
`Utility issue fee (or reissue)
`Design issue fee
`
`144 600
`
`244 300
`
`Plant issue fee(\.f;
`
`122 130
`
`122 130
`
`Petitions to the 'q~inmlssioner
`
`123
`
`50
`
`123
`
`50
`
`Petitions related to provisional applications
`
`126 240
`
`126 240
`
`Submission of Information Disclosure Stmt
`
`581
`
`40 581
`
`40 Recording each patent assignment per
`property (times number of properties)
`
`40
`
`146 710 246 355 Filing a submission after final rejection
`(37 CFR § 1.129(a))
`
`149 710 249 355 For each additional invention to be
`examined (37 CFR § 1.129(b))
`
`179 710 279 355 Request for Continued Examination (RCE)
`169 soo· 169 900 Request for expedited examination
`of a design application
`
`Other fee (s~ecifY) .. ~ - - - - - - - -
`
`• Reduced by·,l~\f:~~j~g Fee Paid
`
`SUBTOTAL (3)
`
`\{$)
`
`40
`
`SUBMITTED BY
`
`Name/(Print!Type)
`
`Signature
`
`Brian Roffe
`
`Complete /if applicable)
`Telephone 516 295-1394
`1 20 01
`Date
`WARNING: Information on this form may become public. Credit card Information should not
`be Included on this form. Provide credit card Information and authorization on PTO-2038.
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`20231. DO NOT SEND FEES OR COMPLETED FORMS TO THIS ADDRESS. SEND TO: Assistant Commissioner for Patent~! Washington·, DC 20231.
`
`9
`
`

`

`-------------- - - - - - - - - - -~
`
`AUTOMOTIVE ELECTRONIC SAFETY NETWORK
`
`ATI-247
`
`CROSS REFERENCE TO RELATED APPLICATIONS
`
`5
`
`This application is . a continuation-in-part application of U.S. patent application Ser. No.
`\I\Ovl 1,(.$.P,,T.t-ei- "',1HJ3').-fR >
`09/073,403 filed May 6, 1998.1'.which is a continuation-in-part of U.S. patent application Ser. No.
`
`08/571,247 filed Dec. 12, 1995, now U.S. Pat. No. 5,772,238 and which is a continuation-in-part of U.S.
`
`patent application Ser. No. 08/550,217 filed Oct. 30, 1995, now abandoned.
`
`10
`
`This application also is a continuation-in-part of U.S. patent application Ser. No. 09/356,314, filed
`ii {I W i),SJJJ,. f/i t; 3-~ b,70'f
`Jul. 16, 1999, which is a corttinuation-in-part of U.S. patent application Ser. No. 08/947,661 filed Oct. 9,
`/,
`1997, now abandoned, and a continuation-in-part of U.S. patent application Ser. No. 09/137,918 filed Aug.
`vtO~ 1.A.'Hc-T. Wo .. (p J I 15; 1 <J 7 ,
`20, 1998,Ahich in turn is a continuation-in-part of U.S. patent application Ser. No. 08/476,077 filed Jun.
`
`7, 1995, now U.S. Pat. No. 5,809,437, which is incorporated herein by reference in its entirety.
`
`This invention also claims domestic priority of U.S. provisional patent application Ser. No.
`o9
`60/028,046 filed October _J,.0"; 1996 through U.S. patent application Ser. No. 08/947,661 filed Oct. 9, 1997.
`
`15
`
`This application is related to U.S. patent application Ser. No. 08/247, 763 entitled "Film Airbags"
`
`filed May 23, 1994, now U.S. Pat. No. 5,505,485 and U.S. patent application Ser. No. 08/539,676 entitled
`
`"Airbag System With Self Shaping Airbag", filed Oct. 5, 1995, now U.S. Pat. No. 5,653,464, all of which
`
`provide pertinent disclosure relative to this specification and are incorporated by reference herein.
`
`20
`
`This invention is also related to U.S. Pat. No. 5,457,293 by the same inventor entitled "Inertia or
`
`Gravity Responsive Tilt Switch", the disclosure of which is hereby incorporated by reference herein.
`
`FIELD OF THE INVENTION
`
`This invention is. in the general field of wiring systems applied to vehicles and particularly to motor
`
`25
`
`vehicles such as automobiles. It specifically addresses the use of a common wire bus or data bus for a
`
`plurality of sensors and actuators in a motor vehicle and particularly for safety systems including crash,
`
`occupant and other sensors, airbag modules and associated electronics.
`
`This invention also relates to the field of inflator devices for inflating airbag occupant restraints
`
`30
`
`mainly for the protection of occupants of automobiles and trucks although it also is applicable to the
`I
`protection of occupants of other vehicles and for inflating other it#).atable objects. In particular, by means
`of th/ present invention, a more efficient utilization of the energy in a propellant is attained resulting in the
`
`need for a lower amount of propellant than in currently existing inflators, and thus a smaller inflator, to
`
`1
`
`10
`
`

`

`- - - - - - - - - - - · --~----·--... --
`
`inflate a given size inflatable object. This is accomplished in part through a more efficient aspirating
`
`nozzle design and an improved geometry of a gas generator that houses the propellant.
`
`The present invention additionally relates to an airbag system for use in vehicles having multiple
`
`airbags where the possibility exists that more than· two airbags will be deployed in a given accident
`
`5
`
`resulting in excessive pressure within the passenger compartment of the vehicle, and which optionally
`
`utilize the inflator devices described above.
`
`The present invention also relates to airbag systems including inflator devices using wider classes
`
`of propellants that produce gases that are toxic to humans if breathed for an extended time period.
`
`The present invention additionally relates to an efficient airbag module whereby much of the
`
`10
`
`electronics which are part of the airbag system are associated with the module including occupant sensing
`
`components, the backup power supply and diagnostic circuitry.
`
`BACKGROUND OF THE INVENTION
`
`It is not uncommon for an automotive vehicle today to have many motors, other actuators, lights
`
`/"ll,, 15
`
`•;::Pt
`
`etc., controlled by one hundred or more switches and fifty or more relays and connected together by almost
`
`five hundred meters of wire, and close to one thousand pin connections grouped in various numbers into
`
`connectors. It is not surprising therefore that the electrical system in a vehicle is by far the most unreliable
`
`system of the vehicle and the probable cause of most warranty repairs.
`
`Unfortunately, the automobile industry is talcing a piecemeal approach to solving this problem
`
`20
`
`when a revolutionary approach is called for.
`
`Indeed, the current trend in the automotive industry is to
`
`group several devices of the vehicle's electrical system together which are located geometrically or
`
`physically in the same area of the vehicle and connect them to a zone module which is then connected by
`
`communication and power buses to the remainder of the vehicle's electrical system. The resulting hybrid
`
`systems still contain substantially the same number and assortment of connectors with only about a 20%
`
`25
`
`reduction in the amount of wire in the vehicle.
`
`Most airbag modules in use today are large, heavy, expensive, and inefficient. As a result, airbags
`
`are now primarily only used for protecting the passenger and driver in a frontal impact, although at least
`
`three automobile manufacturers currently offer a small airbag providing limited protection in side impacts
`·,
`and some are . now offering head protection airbags. The main advantage of airbags over other energy
`I
`absorbing structures is that they utilize the space between the c:,ccupant and vehicle interior surfaces to
`
`. •
`
`'·
`
`3 0
`
`I
`
`absorb the kinetic energy of the occupant during a crash, cushioning the impending impact of the occupant
`
`with the vehicle interior surfaces. Airbags have been so successful in frontal impacts that it is only a
`
`2
`
`11
`
`

`

`matter of time before they are effectively used for side impact protection in all vehicles, protection for rear
`
`seat occupants and in place of current knee bolsters. Substantial improvements, however, must be made in
`
`airbags before they assume many of these additional tasks
`
`A good place to start describing the problems with current airbags is with a calculation of the
`
`5
`
`amount of energy used in a typical airbag inflator and how much energy is required to inflate an airbag. By
`
`one analysis, the chemical propellant in a typical driver's side inflator contains approximately 50,000 foot
`
`pounds (68,000 joules) of energy. A calculation made to determine the energy required to inflate a driver's
`
`side airbag yields an estimate of about 500 foot pounds (680 joules). A comparison of these numbers
`
`10
`
`shows that approximately 99% of the energy in a chemical propellant is lost, that is, generated but not
`needed for inflation of the airbag. One reason for this is that there is a mismatch between the output of a
`In engineering this is known as an
`burning propellant and the inflation requirements of an airbag.
`
`impedance mismatch. Stated simply, propellants naturally produce gases having high temperatures and
`
`high pressures and low gas flow rates. Airbags, on the other hand, need gases with low temperatures and
`
`low pressures and high gas flow rates.
`
`15
`
`In view of this impedance mismatch, inflators are, in theory at least, many times larger then they
`would have to be if the energy of the propellant contained within the. infl~t.~r were efficiently utilized. Some
`
`attempts to partially solve this problem have resulted in a so-called "hybrid" inflator where a stored
`
`pressurized gas is heated by a propellant to inflate the airbag. Such systems are considerably more energy
`
`efficient, however, they also require a container of high pressure gas and means for monitoring the pressure
`
`20
`
`in that container. Other systems have attempted to use aspiration techniques, but because of the geometry
`
`constraints of current car inflator designs and mounting locations, and for other reasons, currently used
`
`aspiration systems are only able to draw significantly less than 30% of the gas needed to inflate an airbag
`
`from the passenger compartment. Theoretical studies have shown that as much as 90% or more of the gas
`
`could be obtained in this manner.
`
`25
`
`Furthermore, since inflators are large and in,e~~i~nt, severe restrictions have been placed on the
`
`type of propellants that can be used since the combustion products of the propellant must be breathable by
`
`automobile occupants. It is of little value to save an occupant from death in an automobile accident only to
`
`suffocate him from an excessive amount of carbon dioxide in the air within the passenger compartment
`
`after the accident. If inflators operated more efficiently, then alternate, more efficient but slightly toxic
`I
`propeli~ts could be used. Also, most current inflators are made from propellants, namely sodium azide,
`
`30
`
`whicH are not totally consumed. Only about 40% of the mass of sodium azide propellants currently being
`
`used, for example, enters the airbag as gas. This residual mass is very hot and requires the inflator to be
`
`3
`
`12
`
`

`

`mounted away from combustible materials further adding to the mass and size of the airbag system and
`
`restricts the materials .that can be used for the inflator.
`
`It is a persistent problem in the art that many people are being seriously injured or even killed
`
`today by the airbag itself. This generally happens when an occupant is out-of-position and against an
`
`5
`
`In order to open the module cover, sometimes called the
`airbag module when the airbag deploys.
`deployment door, substantial pressure must first build up in the airbag before enough force is generated to
`
`burst open the cover. This pressure is even greater if the occupant is in a position that prevents the door
`
`from opening. As a result, work is underway to substantially reduce the amount of energy required to open
`
`the deployment doors and devices have been developed which pop off the deployment door or else cut the
`
`10
`
`deployment door material using pyrotechnics, for example.
`
`One reason that this is such a significant problem is that the airbag module itself is quite large and,
`
`in particular, the airbags are made out of thick, heavy material and packaged in a poor, folded geometry.
`
`The airbag, for example, which protects the passenger is housed in a module which is typically about one
`
`third as long as the deployed airbag. All of this heavy airbag material must be rolled and folded inside this
`
`1!/U
`\11,t
`
`15
`
`comparatively small module, thus requiring substantial energy to unfold during deployment. This situation
`
`could be substantially improved if the airb~ module were to have an alternate geometry and if the airbag
`
`material were substantially lighter and thinner and, therefore, less massive and folded mainly parallel to the
`
`inflator. Even the time to deploy the airbag is substantially affected by the mass of the airbag material and
`
`the need to unfold an airbag with a complicated folding pattern. Parallel folding, as used herein, means that
`
`the airbag material is folded with the fold lines substantially parallel to the axis of the inflator without being
`
`m 20
`
`folded over lengthwise as is now done with conventional airbag folding patterns.
`
`Devices are now being offered on vehiql~~ that will monitor the position of the occupant and
`
`prevent the airbag from deploying if the occupant is dangerously close to the module where he or she can
`
`be seriously injured by the deployment. Some systems will also prevent deployment if the seat in
`
`25
`
`connection with which the airbag operates is unoccupied. An alternate approach is to move the deployment
`
`doors to a location away from normal occupant positions. One such location is the ceiling of the vehicle.
`
`One problem with ceiiing mounted airbags is that the distance required for the airbag to travel, in some
`
`cases, is longer and therefore a larger airbag is needed with greater deployment time. With the use of light
`
`airbag materials, such as thin plastic film, as disclosed in the above-referenced U.S. Pat. Nos. 5,505,485
`
`3 0
`
`and 5,653,464, and the use of more efficient inflators, both of these problems can be solved especially for
`
`the frpnt and rear seat passenger~. The driver poses a different problem since it would be difficult to
`
`position a ceiling mounted airbag module where the airbag would always be projected properly between the
`
`4
`
`13
`
`

`

`_________ , -----
`
`occupant and the steering wheel. On the other hand, the driver can usually ride down on the steering wheel
`
`if he or she is initially positioned close to it.
`
`This problem for the driver's airbag system is not the concept of mounting the airbag on the
`
`ceiling, but the design of the steering wheel and steering column. These designs come from the time when
`
`5
`
`the only way of steering an automobile was through mechanical linkages. The majority of vehicles
`
`manufactured today have power assisted steering systems and, in fact, most drivers would have difficulty
`
`steering a car today if the power steering failed.
`
`If servo power steering were used, the need for a
`
`mechanical linkage between a steering wheel, or other such device, and the power steering system would no
`
`longer be necessary. Servo power steering for the purposes here will mean those cases where the linkage
`
`l O
`
`between the manually operated steering device, which regardless of what that device is, will herein be called
`
`a steering wheel, is done with a servo system either electrically or hydraulically and the system does not
`
`have an operative mechanical connection between the steering wheel and the steering mechanism which
`
`moves the wheels.
`
`The problem of educating the general population, which has become secure in the feeling of a
`
`15
`
`steering wheel and steering column, might be insurmountable if it were not for the substantial safety
`
`advantage resulting from substituting servo power steering for conventional steering systems and using a
`
`non-steering wheel mounted airbag module for the driver.
`
`The steering wheel and steering, column are among the most dangerous parts of the vehicle to the
`
`occupant. Small people, for example, who are wearing seatbelts can still be seriously injured or killed in
`
`20
`
`accidents as their faces slam into the steering wheel hubs. The problem of properly positioning an airbag,
`
`when the comfort and convenience features of telescoping and til

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