111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US007481453B2
`
`c12) United States Patent
`Breed
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,481,453 B2
`Jan.27,2009
`
`(54)
`
`INFLATOR SYSTEM
`
`(56)
`
`References Cited
`
`(75)
`
`Inventor: David S. Breed, Boonton Township,
`Morris County, NJ (US)
`
`(73) Assignee: Automotive Technologies
`International, Inc., Denville, NJ (US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 307 days.
`
`(21) Appl. No.: 11/131,623
`
`(22) Filed:
`
`May 18,2005
`
`(65)
`
`Prior Publication Data
`
`US 2007/0228703 AI
`
`Oct. 4, 2007
`
`Related U.S. Application Data
`
`(63) Continuation-in-part of application No. 10/974,919,
`filed on Oct. 27, 2004, now Pat. No. 7,040,653, and a
`continuation-in-part of application No. 10/817,379,
`filed on Apr. 2, 2004, now abandoned, and a continu(cid:173)
`ation-in-part of application No. 10/638,743, filed on
`Aug. 11, 2003, and a continuation-in-part of applica(cid:173)
`tion No. 10/278,721, filed on Oct. 23, 2002, and a
`continuation-in-part of application No. 10/043,557,
`filed on Jan. 11, 2002, now Pat. No. 6,905,135.
`
`(51)
`
`Int. Cl.
`B60R 21116
`(2006.01)
`B60R 21130
`(2006.01)
`(52) U.S. Cl. ....................................... 280/738; 280/740
`(58) Field of Classification Search . ... ... ... ... .. .. 280/736,
`280/738, 739, 740, 741, 742, 728.2, 730.1,
`280/730.2, 732
`See application file for complete search history.
`
`U.S. PATENT DOCUMENTS
`
`9/1936 Coanda
`2,052,869 A
`1111964 Young eta!.
`3,158,314 A
`9/1965 Hadeler
`3,204,862 A
`2/1968 Day
`3,370,784 A
`12/1968 Oldberg et a!.
`3,414,292 A
`111972 Hass
`3,632,133 A
`2/1974 Hamilton
`3,791,669 A
`4/1974 Karter et al.
`3,801,127 A
`9/1975 Stewart
`3,909,037 A
`3,910,595 A * 10/1975 Karter et al.
`................ 280/732
`2/1976 Giorgini et al.
`3,938,826 A
`3/1976 Schwanz
`3,947,056 A
`8/1977 Hattori et a!.
`4,043,572 A
`12/1978 Shaunnessey
`4,130,298 A
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`GB
`
`2191450
`
`12/1987
`
`Primary Examiner-Eric Culbreth
`Assistant Examiner-Joseph Rocca
`(74) Attorney, Agent, or Firm-Brian Roffe
`
`(57)
`
`ABSTRACT
`
`Method for inflating an airbag in a vehicle to protect an
`occupant in the event of a crash involving the vehicle in which
`an inflator having a propellant is arranged in the vehicle, the
`propellant is ignited after determination of a crash involving
`the vehicle to generate gas therefrom, the gas is directed into
`an airbag and pressure in the airbag is controlled based on the
`occupant by varying the flow of gas into the airbag. Variation
`in the flow of gas into the airbag may be obtained by varying
`a flow of aspirating gas into a mixing chamber in which the
`aspirating gas mixes with gas generated from the propellant.
`
`48 Claims, 50 Drawing Sheets
`
`Page 1 of 192
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`US 7,481,453 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`4/1983 Davis et al.
`4,380,346 A
`5/1989 Hayashi et a!.
`4,833,996 A
`4,877,264 A * 10/1989 Cuevas ....................... 280/731
`4,909,549 A
`3/1990 Pool eta!.
`4,928,991 A
`5/1990 Thorn
`5,004,586 A
`4/1991 Hayashi et a!.
`5,060,973 A
`10/1991 Giovanetti
`5,078,422 A *
`111992 Hamilton et a!. ............ 280/736
`5,085,465 A
`2/1992 Hieahim
`5,100,172 A * 3/1992 Van Voorhies eta!. ....... 280/738
`5,129,674 A
`7/1992 Levosinski
`5,193,847 A
`3/1993 Nakayama
`5,207,450 A
`5/1993 Pack, Jr. et a!.
`5,226,670 A * 7/1993 Wright et a!.
`............... 280/738
`5,286,054 A
`2/1994 Cuevas
`7/1994 Conlee eta!.
`5,332,259 A
`5,366,242 A * 1111994 Faigle eta!. ................ 280/736
`4/1995 Letendre et a!.
`5,406,889 A
`5,423,571 A
`6/1995 Hawthorn
`5,435,594 A
`7/1995 Gille
`5,435,595 A
`7/1995 Lauritzen et a!.
`5,437,473 A
`8/1995 Henseler
`10/1995 Marts eta!.
`5,458,367 A
`
`5,489,117 A
`5,509,686 A
`5,599,042 A
`5,623,115 A *
`5,743,558 A *
`5,772,238 A
`5,951,040 A
`5,984,352 A
`6,142,515 A
`6,179,326 B1
`6,227,565 B1
`6,290,256 B1
`6,314,889 B1
`6,315,322 B1
`6,533,316 B2
`6,543,805 B2
`6,648,367 B2
`6,655,712 B1
`6,702,323 B2
`6,733,036 B2
`6,905,135 B2
`2003/0209894 A1
`2004/0145166 A1
`* cited by examiner
`
`2/1996 Huber
`4/1996 Shepherd et a!.
`2/1997 Shyr eta!.
`4/1997 Lauritzen et a!. .. ... .. ... .. 102/288
`4/1998 Seymour .................... 280/739
`6/1998 Breed eta!.
`9/1999 McFarland et a!.
`1111999 Green, Jr. et a!.
`1112000 Mika
`1/2001 Breed eta!.
`5/2001 McFarland et a!.
`9/2001 McFarland et a!.
`1112001 Smith
`1112001 Mika
`3/2003 Breed eta!.
`4/2003 McFarland et a!.
`1112003 Breed eta!.
`12/2003 Larsen eta!.
`3/2004 Goetz
`5/2004 Breed eta!.
`6/2005 Breed
`1112003 Larsen eta!.
`7/2004 Smith
`
`Page 2 of 192
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`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 1 of 50
`
`US 7,481,453 B2
`
`~54
`
`52
`
`I
`
`51, )
`~/
`tft~ii'tC -, ~
`~ lij
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`~J
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`I g..s-sG- _ I \
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`~ ) /0'0~1
`J [ )
`
`53-''
`
`Pig.1
`
`Pig. 1;4
`
`Pig. 2
`
`Page 3 of 192
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`KSS 1025
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`U.S. Patent
`
`Jan.27,2009
`
`Sheet 2 of 50
`
`US 7,481,453 B2
`
`NEURAL NETWORK SINGLE POINT, PASSENGER COMPARTMENT MOUNTED SENSOR PERFORMANCE
`
`SCALED
`VELOCITY
`
`8MPH
`10 MPH
`12MPH
`14MPH
`16MPH
`18MPH
`20MPH
`22MPH
`24MPH
`26MPH
`28MPH
`30MPH
`32MPH
`34 MPH
`
`NT
`NT
`0.0/1.1
`0.0/1.2
`0.0/1.4
`0.0/1.6
`0.0/1.8
`0.0/1.9
`0.0/2.1
`0.0/2.3
`0.0/2.5
`0.0/2.7
`0.0/2.8
`0.0/3.0
`
`BARRIER SCALING FACTOR
`
`1.2
`NT
`0.7/2.9
`0.8/3.5
`0.9/4.1
`0.9/4.4
`0.8/4.2
`0.7/4.3
`0.5/3.9
`0.1/2.3
`0.1/2.5
`0.0/2.1
`0.0/2.3
`0.0/2.4
`0.0/2.3
`
`1.4
`NT
`0.9/3.1
`0.9/3.5
`1.0/3.8
`1.0/4.0
`0.7/3.6
`0.7/4.0
`0.7/4.0
`0.8/4.4
`0.5/4.0
`0.1/2.4
`0.1/2.6
`0.1/2.8
`0.0/2.0
`
`Pig. 3
`
`1.6
`NT
`1.0/3.0
`1.0/3.4
`1.2/4.0
`1.1/4.0
`1.2/4.5
`1.1/4.3
`0.9/4.1
`0.8/4.2
`0.9/4.5
`0.7/4.2
`0.1/2.3
`0.1/2.5
`0.0/1.8
`
`1.8
`NT
`NT
`1.4/3.9
`1.3/4.0
`1.4/4.3
`1.6/4.8
`1.3/4.4
`1.2/4.6
`1.3/5.0
`1.0/4.4
`0.8/4.1
`0.8/4.4
`0.9/4.7
`0.6/4.2
`
`2
`NT
`NT
`2.0/4.7
`1.7/4.5
`1.7/4.6
`1.8/4.9
`1.0/3.8
`1.1/4.2
`1.4/4.8
`1.2/4.6
`0.5/3.2
`1.2/5.0
`1.1/4.9
`1.2/5.3
`
`OPTIMIZED SINGLE POINT, PASSENGER COMPARTMENT MOUNTED SENSOR PERFORMANCE
`
`SCALED
`VELOCITY
`
`BARRIER SCALING FACTOR
`
`8MPH
`10 MPH
`12 MPH
`14 MPH
`16 MPH
`18 MPH
`20 MPH
`22 MPH
`24 MPH
`26 MPH
`28 MPH
`30 MPH
`32 MPH
`34 MPH
`
`NT
`4.7/10.3*
`2.2/6.7
`2.2/7.2
`2.2/7.6
`2.2/8.0
`2.0/7.9
`1.0/5.3
`.5/4.2
`.4/4
`.4/4.1
`.4/4.2
`.3/4.2
`.3/4.0
`
`1.2
`NT
`NT
`5.8/12.1
`2.7/7.5
`2.7/7.9
`2.8/8.7
`3.1/9.3
`2.7/8.9
`1.6/6.5
`1.2/5.7
`.6/4.0
`.5/4.0
`.5/4.1
`.5/4.2
`
`1.4
`NT
`NT
`NT
`3.9/8.9
`3.4/8.5
`3.6/9.2
`3.7/9.7
`3.9/10.4
`3.9/10.8
`2.0/6.8
`1.8/6.6
`.8/4.2
`.7/7.2
`.7/4.3
`
`Pig. 4
`
`1.6
`NT
`NT
`NT
`NT
`4.2/9.3
`4.2/9.7
`4.3/11.2
`4.5/10.9
`4.8/11.6
`4.5/11.5
`2.7/7.8
`2.2/6.9
`2.1/7.0
`.9/4.5
`
`1.8
`NT
`NT
`NT
`NT
`NT
`5.0/10.5
`5.0/10.9
`5.2/11.5
`5.4/12.0
`5.8/13
`5.9/13.5
`6.4/14.5
`2.6/7.4
`2.6/7.5
`
`2
`NT
`NT
`NT
`NT
`NT
`17.8/27.5
`5.9/11.7
`5.9/12.2
`6.1/12.8
`6.4113.5
`6.8/14.4
`7.1/15.1
`3.4/8.4
`4.0/9.6
`
`Page 4 of 192
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`Jan.27,2009
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`Sheet 3 of 50
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`US 7,481,453 B2
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`7
`
`15
`
`L
`
`72
`
`71
`
`9
`
`~5
`
`74
`
`73
`
`Piq.s
`
`6
`
`77
`
`Piq.6
`
`Piq. 7
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`Page 5 of 192
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`Jan.27,2009
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`Sheet 4 of 50
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`US 7,481,453 B2
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`80
`
`81
`
`8
`
`(8 1
`
`95
`
`93
`
`92
`
`80
`
`~(
`
`83
`
`Pig. 7.ft_
`
`Pig. 7(}J
`
`Pifi.8
`
`Pig.9
`
`1 6
`
`Pig.11
`
`99
`
`GJ
`RUBBER
`
`•
`TIN COATED BRASS
`Pifi.12
`
`D
`PLASTIC
`
`Page 6 of 192
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`Sheet 5 of 50
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`US 7,481,453 B2
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`75
`)
`
`74
`
`73
`
`J r r
`~l
`~
`96__)
`Piq.13
`
`Piq.15
`
`Piq.17
`
`Pig. 18
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`Page 7 of 192
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`Sheet 6 of 50
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`US 7,481,453 B2
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`SIDE IMPACT
`CRUSHZONE
`(r SENSOR
`
`159
`~
`
`)~
`
`./
`158
`~-!ELECTRONIC
`SENSOR
`
`----
`
`Pig. 19
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`164
`
`Piq. 21(8
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`Pasalapr Ccm:cpadmeut
`165
`\ Bloctmaic Cl88h ___)
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`Seaaar
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`'
`---re~l
`
`166__)
`
`Piq.21C
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`Page 8 of 192
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`Sheet 7 of 50
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`US 7,481,453 B2
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`Plfj. 21cD
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`Plfi.22
`192
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`193
`
`Plfi.23
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`Page 9 of 192
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`US 7,481,453 B2
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`Pl(i.24
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`213
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`212
`
`PI(i.25
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`22~,
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`Pig. 26
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`US 7,481,453 B2
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`1!.111 ;:::( ==~====)~-
`sees
`IBSQI
`I
`1
`
`Pig. 26.Jl
`
`Anticipatory
`Accelerometer
`occupant
`Sensor ~/Crash Sensor
`
`Control
`Module
`
`240
`
`Piq.27
`
`Pig. 28
`
`-------------(cid:173)
`Airbag ~ _ _._..Atmosphere
`Gas Generator _ ___,5-,._/
`'------------/
`Atmosphere
`
`Piq. 29
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`US 7,481,453 B2
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`9
`
`Piq.3o
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`22
`
`7 Cellular Phone
`
`Diagnostic
`Module
`
`Piq. 31
`
`.JNO
`
`f](j.32
`
`Prevenl
`~e-entry
`of vehK:Ie
`onfo roodway
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`US 7,481,453 B2
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`~62
`
`~64
`
`Component
`operation
`monitoring
`system
`
`Operational satellite-
`based I ground-based
`location determining
`svstem
`
`3 1
`
`~66
`Pig. 33
`
`Guidance
`system
`
`30
`
`I.
`
`303
`\
`
`307
`
`\:~0
`
`Piq.34
`
`311
`
`313
`
`Piq.35
`
`•
`
`6. Redesi
`
`the network if necessa
`
`7. Output neural network algorithm.
`
`Obtain data from staged crashes and other
`non-crash events plus occupant position
`weight, size, velocity etc. from sled tests
`~
`2. Analytically derive additional crash and
`event data from staged crashes and
`analytically determine occupant motion.
`
`3. Design candidate neural network.
`
`+
`•
`
`Pig. 36
`
`1+-
`
`4. Train the candidate neural network.
`t
`5. Test the neural network using different data .
`
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`343
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`Pig.37
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`323
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`38
`28
`327_j
`
`324
`
`Pig.38
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`325
`
`PRIOR ART
`354
`
`351
`
`PRIOR ART
`351 352
`354 359
`
`PRIOR ART
`350
`352
`
`55
`
`Pig. 39
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`Pig.40
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`Pig. 41
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`374
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`Pig. 42
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`Piq. 43
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`379
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`Piq. 44
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`393 390
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`Pig. 45-A
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`382
`
`393
`
`92
`
`Pig. 46ft
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`389
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`Piq. 45
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`392
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`Pig.46
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`Pig.47
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`Piq. 47}1
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`Piq. 49
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`Piq.4B
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`409
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`~~1
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`Piq.so
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`61
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`431
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`30
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`45
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`Piq. 52
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`Plfi. 53ft
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`Plfi.53(]J
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`Plfi.53C
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`459
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`43~
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`43
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`PlrJ.53P.
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`PlrJ. 53(])
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`436
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`444
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`451
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`PlrJ. 53P
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`443
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`Piq.53q
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`441
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`446
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`445
`444
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`433
`+
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`[439
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`Piq. 6,U
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`508
`509
`Piq. 62<B
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`Piq. 63
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`517
`518
`519
`515
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`520
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`Piq. 65
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`523 52 ~531
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`Pig. 650
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`Pig.66tB
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`Pig.68
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`57
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`71A.
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`601
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`573
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`Piq. 70
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`Piq. 71(]J
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`602
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`Piq. 71.ft
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`Piq. 71C
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`Piq. 72
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`Piq. 73
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`Piq. 74!B
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`831
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`Piq. 74A
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`23
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`
`Piq. 7#:>
`
`Page 24 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 23 of 50
`
`US 7,481,453 B2
`
`640
`
`642
`647
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`643
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`646
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`672
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`676
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`687
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`Piq.ao
`
`Page 25 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 24 of 50
`
`US 7,481,453 B2
`
`Piq. 85
`
`Piq.86
`
`Page 26 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 25 of 50
`
`US 7,481,453 B2
`
`Piq.87
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`735
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`Piq. 88(])
`
`Page 27 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 26 of 50
`
`US 7,481,453 B2
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`f£1(]. 89
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`Page 28 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 27 of 50
`
`US 7,481,453 B2
`
`Piq.94
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`Page 29 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 28 of 50
`
`US 7,481,453 B2
`
`~811
`PI(]. 98C ~812
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`812
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`Piq. 98(/)
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`817
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`PI(]. 98t] "------ 818
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`Page 30 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 29 of 50
`
`US 7,481,453 B2
`
`820
`Piq. 981
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`Page 31 of 192
`
`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 30 of 50
`
`US 7,481,453 B2
`
`CHEST ACCELERATION AND OCCUPANT
`MOTION WITH A CONVENTIONAL AIR BAG
`
`40-r-----.-----.-----.-----.-----.----~
`
`I
`(.)
`~
`I-
`~ 30~-----r-----r----~~---r-----r----~
`~ w
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`0
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`25
`
`150
`75
`100
`125
`50
`TIME (MILLISECOND) Piq.101
`
`CHEST ACCELERATION AND OCCUPANT
`MOTION WITH A VARIABLE-VENT AIRBAG
`
`40-r-----.-----.-----.-----.-----.----~
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`CHESTG
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`125
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`50
`TIME (MILLISECOND) Piq.102
`
`(!)
`
`Page 32 of 192
`
`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 31 of 50
`
`US 7,481,453 B2
`
`&847A
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`Piq.1D3CB
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`Piq.1D3
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`Piq.1D5
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`Piq.1D6
`
`Page 33 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 32 of 50
`
`US 7,481,453 B2
`
`Pig.107_ft
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`Pig.t07(}J
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`~1
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`868 ~ c .......
`
`69867
`
`Pig.tOB_ft
`
`Pig.108(}J
`
`Pig.109
`
`Airbag
`Interior
`
`<:::..!if:
`
`873 872:::5873
`I _871
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`841
`
`Pig. 109ft
`
`Pig.109(}J
`
`876
`Pig.11fXB
`
`Page 34 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 33 of 50
`
`US 7,481,453 B2
`
`Piq.111.ft_
`
`Piq.112
`
`Piq. 111(JJ
`
`Airbag
`Interior
`
`- - - Hler as~~;t rolio=25
`· · - Fi.lct DSi)eCt ratio•)(}
`-
`----- R1ler aspect rotJo .. 75
`- - Fitler as;Jeetrotio .. 100
`- - eKpcrimental
`
`I
`I
`
`I
`
`I
`
`/ / / /
`
`~----·
`
`Volume fraction of filler
`
`Piq.113
`
`Weight % Microlite
`
`Piq. 114
`
`2W
`
`200
`
`c
`0
`t)
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`:0 :oo
`0
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`05
`"-
`
`50
`
`Page 35 of 192
`
`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 34 of 50
`
`US 7,481,453 B2
`
`c "' om
`:t= \60
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`
`MAXIMUM % SOLIDS WITH VARYING
`MICROLITE [W/BL 1 00)
`
`en
`:Qn
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`Weight % Microlite
`f£1(].115
`
`'~o ~~~-7--~~,~~~--7~~~~~
`% Microlite
`PI(j.116
`
`BUlYL/FILLER RATIO FOR
`VARYING MICROLITE
`[W/BL 1 00)
`
`-+-Before
`--11---After
`
`% Microlite
`PI(j.117
`
`"Weight % IV'Iicrolife
`PI(j.118
`
`+Normal(l)
`
`¢Normal(2)
`
`A.Carcass(l)
`
`LI.Carcass(2)
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`ocoated(l)
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`0
`10
`20
`30
`Time [days)
`PI(j.119
`
`40
`
`Page 36 of 192
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`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 35 of 50
`
`US 7,481,453 B2
`
`~y---911
`Plf!.124.ft.~
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`
`Pif!.125
`
`Page 37 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 36 of 50
`
`US 7,481,453 B2
`
`r-- 914
`t
`
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`919
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`Piq.126.ft
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`Piq.127.ft
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`Piq.12fiB
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`Piq.127(}J
`
`Page 38 of 192
`
`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 37 of 50
`
`US 7,481,453 B2
`
`FIG. 128
`
`Page 39 of 192
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`KSS 1025
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`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 38 of 50
`
`US 7,481,453 B2
`
`FIG. 129
`
`FIG. 130
`
`Page 40 of 192
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`KSS 1025
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`
`U.S. Patent
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`Jan.27,2009
`
`Sheet 39 of 50
`
`US 7,481,453 B2
`
`FIG. 131
`
`FIG. 132
`
`Page 41 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 40 of 50
`
`US 7,481,453 B2
`
`FIG. 133
`
`FIG. 134
`
`FIG. 135
`
`10
`
`20
`
`30
`
`40
`
`50
`
`60
`
`70
`
`80
`
`90 Vb~8Rto
`
`Page 42 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 41 of 50
`
`US 7,481,453 B2
`
`FIG. 136
`
`I
`
`p
`¢=:JJ._._._ ........... ~~_[~"""""'-
`
`FIG. 137
`
`FIG. 138
`
`PowerGraphic:s
`EFAC!!T=l
`AVR!!S=Mat
`SMX =610. 316
`0
`76.29
`-
`~ 152.579
`-
`-
`
`228.869 = 305.158
`
`~ 381.448
`~ 457.737
`L.......J 534.027
`610.316
`
`-
`
`Page 43 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 42 of 50
`
`US 7,481,453 B2
`
`FIG. 139
`
`FIG. 140
`
`Page 44 of 192
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 43 of 50
`
`US 7,481,453 B2
`
`,
`- T -
`
`-
`
`-
`
`-
`
`-
`
`-
`
`-
`
`-
`
`-
`
`-
`
`-
`
`,
`- -,-- -
`
`20atm - -
`- -30atm - -
`40atm-
`
`sao,
`
`5001
`
`4001
`.IE
`E
`>300
`
`200
`
`100
`
`0 oL-----O.~OL0_2---0~.J0~04----0~.J0~06----0~.~0~08~--~-
`dist. m
`
`'" Q.
`"' "'-40
`
`~
`Q.
`-60
`
`-80
`
`-
`
`-
`
`-
`
`0
`
`'
`
`I
`- L -
`I
`0.02
`
`-
`
`-
`
`-
`
`'
`j
`
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`
`-
`
`-
`
`I
`0.04
`
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`1
`- _I_ - -3()atm -
`40atm-
`I
`0.1
`0.12
`0.08
`
`-
`
`I
`- _I- -
`I
`0.06
`dist. m
`
`FIG. 141A
`
`FIG. 141B
`
`Or-~------------------------,
`
`~=fl ~==
`i:/; CT T,L:-
`
`3Qatm-
`40alm-
`1
`0.008
`0.01
`
`_100 1
`0
`
`1
`
`I
`
`1
`
`0.002
`
`0.006
`0.004
`dist. m
`
`FIG. 141C
`
`40
`
`Pav = 21,6 atm
`
`~ 30
`.¥
`
`Cl>
`... 20
`::::J
`Ill
`Ill
`~ 10
`ll.
`
`50
`
`150
`100
`Time, ms
`
`200
`
`FIG. 142
`
`Page 45 of 192
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 44 of 50
`
`US 7,481,453 B2
`
`I
`~:~
`,,.:··1 . -
`~.. . ...
`I ,..---··
`'--~.J
`I
`I
`~~
`~~:¢l ~---oto-¢-r-
`
`7,0
`
`6,0
`
`Q,5,0
`Ill
`Ill
`:!1::: 4,0
`
`3,0
`
`2,0
`
`5
`
`I -0.075, calculaled I
`
`j---or5_A
`
`.!
`~ ... .\.
`~
`'\:•
`'{::::-_
`R\.1
`ib ~
`
`...,-;:- ~=''--;o,.-
`
`10
`
`15
`20
`P,atm
`
`25
`
`30
`
`I
`_.-,j
`
`H>
`,,-..-.;;.
`
`~~
`
`o
`075, closed
`---fJT5_A, open
`-07 5 , calc open
`1 -"fJT5. calc closed'
`
`4(X)
`
`350
`
`:m
`li:25l
`~
`1!!200
`j
`-- 150
`a
`
`100
`
`50
`
`0
`
`5
`
`10
`
`15
`P.atm
`
`20
`
`25
`
`30
`
`FIG. 143
`
`FIG. 144
`
`600
`
`500
`
`075-1 ,2,3, closed
`A
`--·-[!,- 075-1
`-075-11
`---l!r- 075-1 closed! calculated
`
`~ m=lll calcu ated
`
`-b.~ 075-1, calculated
`Q, liter/secc nd
`400
`-
`
`:/~
`~
`___--l
`
`,l;
`
`300
`
`200
`
`100
`
`0
`
`5
`
`10,0
`
`9,0
`
`8,0
`
`7,0
`
`K &SR),O
`
`5,0
`
`4,0
`
`3,0
`
`2,0
`
`1,0
`
`0,0
`
`&-
`d ~~~
`~1./A. ~~
`~ ~- _A-A/ ~-~ ~
`
`~
`
`-,
`
`A
`
`~ ~
`
`-t.
`
`~~- :A
`I
`
`10
`15
`FIG. 145
`
`20
`
`25
`
`P, atm
`
`30
`
`35
`
`40
`
`'\
`
`"'
`
`'l,~
`~ ~
`.j~
`~~ ~
`~ ..a-..-----.
`·t;:~ -~
`
`.A=·~"' 0.075_1. calculatl!ld
`
`---+--075_1
`
`-G--075_2
`
`- -6 - 075_2. calculated
`
`--+---075_3
`
`"'D
`
`·--
`
`5
`
`10
`
`15
`FIG. 146
`
`20 P, atm 25
`
`30
`
`35
`
`40
`
`Page 46 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 45 of 50
`
`US 7,481,453 B2
`
`II
`I
`
`-A1~11 I
`I
`
`--A1-V
`
`\~
`~ ~
`~ I'--
`~-~
`
`\
`
`"
`
`10,0
`
`9,0
`
`8,0
`
`7,0
`
`Cl.
`Ill 6,0
`til
`~
`
`5,0
`
`4,0
`
`3,0
`
`2,0
`
`...,. ""
`
`25
`
`30
`
`35
`
`5
`
`10
`
`15
`
`20
`P,atm
`
`FIG. 147
`
`FIG. 148
`
`Page 47 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 46 of 50
`
`US 7,481,453 B2
`
`FIG. 149
`
`900
`
`800
`
`"tJ
`c 700
`0
`u
`G) .!! 600
`~
`~ 500
` 400
`'t:
`
`-~
`
`<( 300 -::l
`
`.& 200
`::l
`0
`~
`1-
`
`100
`
`0
`
`6,0
`
`5,0
`
`4,0
`
`3,0
`
`2,0
`
`1,0
`
`0,0
`
`c.
`II)
`iU
`~
`
`5
`
`10
`
`20
`25
`15
`Inlet Pressure, atm
`
`30
`
`35
`
`I
`I
`I
`j
`-0,100,z-4 I_
`I
`=~
`·~, ~0.100,z-3
`r ·~ I
`. --
`. ~" I
`.I
`.
`~' :=
`'.;:..
`I
`
`---0.100, Z·2
`
`I
`I
`
`:
`
`I
`i
`
`30
`
`5
`
`10
`
`20
`15
`25
`Inlet Pressure, atm
`
`FIG. 150
`
`Page 48 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 47 of 50
`
`US 7,481,453 B2
`
`FIG. 151
`
`----------
`
`I
`I
`I
`,
`I_ ............ ~///,,
`
`t~=:::::._:~_:_::: -
`
`- -X
`
`FIG. 152
`
`FIG. 153
`
`Page 49 of 192
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`KSS 1025
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`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 48 of 50
`
`US 7,481,453 B2
`
`FIG. 154
`
`1200
`
`1000
`
`800
`
`600
`
`400
`
`200
`
`0
`
`5
`
`-
`
`12,0
`11,0
`10,0
`9,0
`8,0
`
`5,0
`4,0
`3,0
`2,0
`1,0
`0,0
`
`:
`
`-
`
`:
`
`5
`
`r;;;
`0
`CJ
`Cll
`.!!!
`!!!
`Cll
`:!::
`t 0
`t
`::;: ... ::::J c.
`... ::::J
`iii ... 0
`
`0
`
`1-
`
`c.
`
`:1::::
`
`7,0 = 6,0
`
`A-6,
`0,100
`
`--0.100, 2z =50-1, open
`
`--0.100, 2z=34,50-1, closed
`
`---0.100. 2z=34-1. open
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`Inlet Pressure, abn
`
`A
`
`.
`'
`-A-0,100, zz-50-1 ~
`.. .., ...
`"X_\.,.
`~8:188: ~~~~=1
`_I
`~ I -o. 100. 2z=50-2
`- -.....__"'1
`
`~I
`~
`
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`FIG. 155
`
`Page 50 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 49 of 50
`
`US 7,481,453 B2
`
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`FIG. 157
`
`Page 51 of 192
`
`KSS 1025
`
`

`
`U.S. Patent
`
`Jan.27,2009
`
`Sheet 50 of 50
`
`US 7,481,453 B2
`
`FIG. 158
`
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`
`Page 52 of 192
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`KSS 1025
`
`

`
`US 7,481,453 B2
`
`1
`INFLATOR SYSTEM
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`2
`patent application Ser. No. 09/753,186 filed Jan. 2,
`2001, now U.S. Pat. No. 6,484,080, which is a con(cid:173)
`tinuation-in-part of U.S. patent application Ser. No.
`09/137,918 filed Aug. 20, 1998, now U.S. Pat. No.
`6,175,787.
`E) a continuation-in-part of U.S. patent application Ser.
`No.10/330,938filedDec. 27, 2002,nowU.S. Pat. No.
`6,823,244;
`4) U.S. patent application Ser. No. 10/817,379 filed Apr. 2,
`2004, now abandoned, which is:
`A. a continuation-in-part of U.S. patent application Ser.
`No. 09/888,575 filed Jun. 25,2001, now U.S. Pat. No.
`6,715,790, which is a continuation-in-part of U.S.
`patent application Ser. No. 09/535,198, filed Mar. 27,
`2000, now U.S. Pat. No. 6,250,668, which is a con(cid:173)
`tinuation-in-part of U.S. patent application Ser. No.
`09/071,801, filed May 4, 1998, now U.S. Pat. No.
`6,149,194, which is a continuation-in-part of:
`1) U.S. patent application Ser. No. 08/626,493, filed
`Apr. 2, 1996,nowU.S. Pat. No. 5,746,446, 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
`2) U.S. patent application Ser. No. 08/795,418, filed
`Feb. 4, 1997, now U.S. Pat. No. 5,863,068; and
`B. a continuation-in part ofU.S. patent application Ser.
`No. 10/413,318 filed Apr. 14, 2003 now abandoned
`which claims priorityunder35 U.S.C. §119(e) ofU.S.
`provisional patent application Ser. No. 60/374,282
`filed Apr. 19, 2002; and
`5) U.S. patentapplicationSer. No.10/974,919 filed Oct. 27,
`2004 now U.S. Pat. No. 7,040,653.
`This application is related to U.S. patent application Ser.
`No. 08/247,763 filed May 23, 1994, now U.S. Pat. No. 5,505,
`485, and U.S. patent application Ser. No. 08/539,676, 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.
`All of the above applications and patents, and any applica(cid:173)
`tions, publications and patents mentioned below, are incor(cid:173)
`porated herein by reference in their entirety and made a part
`hereof.
`
`FIELD OF THE INVENTION
`
`The present invention relates to methods and apparatus for
`sensing a vehicle crash, such as a frontal crash, a side impact,
`a rear impact or a rollover, for the purpose of, for example,
`50 controlling an occupant protection system.
`The present invention also relates to steering wheel assem(cid:173)
`blies for vehicles and vehicles including the same and more
`particularly to steering wheel assemblies which interact with
`an occupant protection system to improve the deployment
`thereof.
`The present invention also relates to a side curtain airbag
`system which deploys to prevent injury to vehicle occupants
`in a side impact or rollover accident.
`The present invention also relates to airbags made from
`plastic film such as a side curtain airbag arranged to deploy
`along the side of a vehicle to protect occupants during a crash
`involving the vehicle, including a rollover. The side curtain
`airbag may even wrap around a front-seated occupant, i.e.,
`have a frontal portion designed to deploy between a front-
`seated occupant and the dashboard. Also there may be a
`plurality plastic film airbags that deploy in the event of a
`vehicle crash. In some cases, such plastic film airbags may
`
`This application is a continuation-in-part of:
`1) U.S. patent application Ser. No. 10/043,557 filed Jan. 11,
`2002, now U.S. Pat. No. 6,905,135 which is a continu(cid:173)
`ation-in-part ofU.S. patent application Ser. No. 09/925,
`062 filed Aug. 8, 2001, now U.S. Pat. No. 6,733,036, 10
`which is a continuation-in-part of U.S. patent applica(cid:173)
`tion Ser. No. 09/767,020 filed Jan. 23, 2001, now U.S.
`Pat. No. 6,533,316, which is:
`A) a continuation-in-part application of U.S. patent
`application Ser. No. 09/073,403 filed May 6, 1998, 15
`now U.S. Pat. No. 6,179,326, which is:
`1) 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
`2) a continuation-in-part of U.S. patent application 20
`Ser. No. 08/550,217 filed Oct. 30, 1995, now aban(cid:173)
`doned;and
`B) a continuation-in-part ofU.S. patent application Ser.
`No. 09/356,314 filed Jul. 16, 1999, now U.S. Pat. No.
`6,326,704, which is:
`1) a continuation-in-part of U.S. patent application
`Ser. No. 08/947,661 filed Oct. 9, 1997, now aban(cid:173)
`doned which claims priority under 35 U.S.C. §119
`(e) of U.S. provisional patent application Ser. No.
`60/028,046 filed Oct. 10, 1996; and
`2) a continuation-in-part of U.S. patent application
`Ser. No. 09/137,918 filed Aug. 20, 1998, now U.S.
`Pat. No. 6,175,787;
`2) U.S. patent application Ser. No. 10/278,721 filed Oct.
`23,2002 claims priorityunder35 U.S.C. §119(e) ofU.S. 35
`provisional patent application Ser. No. 60/348,720 filed
`Oct. 23, 2001;
`3) U.S. patent application Ser. No. 10/638,743 filed Aug.
`11, 2003 which is:
`A) a continuation-in-part ofU.S. patent application Ser. 40
`No. 08/962,827 filed Nov. 3, 1997, now U.S. Pat. No.
`6,609,903 which is a continuation-in-part of U.S.
`patent application Ser. No. 08/476,076 filed Jun. 7,
`1995, now U.S. patent application Ser. No. 05/684,
`701;
`B) a continuation-in-part ofU.S. patent application Ser.
`No. 10/331,060 filed Dec. 27, 2002 which is:
`1) a continuation-in-part of U.S. patent application
`Ser. No. 09/862,530 filed May 22, 2001, now U.S.
`Pat. No. 6,557,889, which is:
`a) a continuation-in-part ofU.S. patent application
`Ser. No. 09/452,735 filed Dec. 1, 1999, now U.S.
`Pat. No. 6,234,519; and
`b) a continuation-in-part ofU.S. patent application
`Ser. No. 09/748,489 filed Dec. 26, 2000, now 55
`U.S. Pat. No. 6,328,126; and
`2) a continuation-in-part of U.S. patent application
`Ser. No. 08/865,525 filed May 29, 1997, now U.S.
`Pat. No. 6,532,408;
`C) a continuation-in-part ofU.S. patent application Ser. 60
`No. 09/435,045 filed Nov. 8, 1999, now U.S. Pat. No.
`6,685,218, which is a continuation-in-part of U.S.
`patent application Ser. No. 09/114,962 filed July 14,
`1998, now U.S. Pat. No. 6,419,265;
`D) a continuation-in-part ofU.S. patent application Ser. 65
`No. 10/188,673 filed Jul. 3, 2002, now U.S. Pat. No.
`6,738,697 which is a continuation-in-part of U.S.
`
`25
`
`30
`
`45
`
`Page 53 of 192
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`

`
`US 7,481,453 B2
`
`3
`deploy to fill substantially all of the front passenger compart(cid:173)
`ment of an automotive or truck vehicle.
`The present invention also relates to airbags having inter(cid:173)
`connected compartments for use in vehicular crashes
`whereby the airbags deploy before or during the crash to
`cushion the occupant of the vehicle and prevent injury to the
`occupant. The present invention also relates to a method for
`making an airbag having interconnected compartments and
`an occupant protection system including an airbag with inter(cid:173)
`connected compartments.
`The present invention also relates to vehicular airbags hav(cid:173)
`ing a low mass and made substantially from thin plastic film
`which are designed to deploy in a crash involving the vehicle
`so that if they impact the vehicle occupant wherever located,
`they will not cause significant injury to the occupant. In order
`to make a film airbag of sufficiently low mass so as not to
`injure the occupant, it has been recognized that the film airbag
`should be designed to arrest the propagation of a tear so that
`a small hole or break in the film does not result in a cata(cid:173)
`strophic failure, i.e., cause the airbag to burst like a balloon or
`otherwise prevent the airbag from deploying properly. One
`particular method of arresting the propagation of a tear of this
`invention is to use a combination of an elastomeric film and a
`reinforcement structure which in certain embodiments may
`be the elastomeric material itself constructed in a variable
`thickness pattern, i.e., have thinner and thicker sections, or in
`a manner so that it has strategically placed thicker sections,
`i.e., relative to remaining portions of the material, in view of
`stress considerations during deployment. Another particular
`method of arresting the propagation of a tear is to formulate 30
`the plastic film so that it exhibits the property of blunting, as
`described below. One method of achieving this property is to
`laminate two or more plastic films having different properties
`together. Typically, one of the films is more rigid and the other
`more elastic. One example is a lamination comprising 35
`NYLON 6,6® and polyurethane films.
`The present invention also relates to airbags including bar(cid:173)
`rier coatings which provide reductions in gas, chemical and
`vapor permeability, especially side curtain airbags.
`The present invention also relates to methods for manufac- 40
`turing airbag modules including an airbag having a barrier
`coating and an associated inflator.
`
`BACKGROUND OF THE INVENTION
`
`The invention relates to several different areas and a dis(cid:173)
`cussion of some particular areas of interest follows. All men(cid:173)
`tioned patents, published patent applications and literature
`are incorporated by reference herein.
`
`1. Crash Sensors
`1.1 Pattern Recognition Approach to Crash Sensing
`Pattern recognition techniques, such as artificial neural
`networks are finding increased application in solving a vari(cid:173)
`ety of problems such as optical character recognition, face
`recognition, voice recognition, and military target identifica(cid:173)
`tion. In the automotive industry in particular, pattern recog(cid:173)
`nition techniques are applied to identifY various objects
`within the passenger compartment of the vehicle, such as a
`rear facing child seat, as well as to identify threatening objects
`with respect to the vehicle, such as an approaching vehicle
`about to impact the side of the vehicle (see, e.g., U.S. Pat. Nos.
`5,829,782, 6,343,810 and U.S. RE37260).
`Pattern recognition techniques are also applied