United States Patent [191
`Warner et al.
`
`[11] Patent Number:
`[45] Date of Patent:
`
`4,966,388
`Oct. 30, 1990
`
`[54]
`
`[75]
`
`INFLATABLE STRUCTURES FOR SIDE
`IMPACT CRASH PROTECTION
`Inventors: Charles Y. Warner; Charles E.
`Strother, both of Orem, Utah; Donald
`E. Struble, Phoenix, Ariz.; Milton G.
`Wille, Provo, Utah
`[73] Assignee: Collision Safety Engineering Inc.,
`Orem, Utah
`[21] Appl. No.: 356,533
`May 25, 1989
`[22] Filed:
`Int. CI.~ ....................... B60R 21/16; B60R 21/00
`[51]
`[52] U.S. CI. ..................................... 280/730; 280/734
`[ S 8] Field of Search ............... 2801730, 728, 731, 732,
`280/743, 734; 180/271
`References Cited
`U.S. PATENT DOCUMENTS
`3,897,961 8/1975 Leising et al ....................... 280/730
`3,927,901 12/1975 Weman ............................... 280/730
`3,981,520 9/1976 Pulling ................................ 280/730
`
`[56]
`
`Primary Examiner-Richard A. Bertsch
`ABSTRACT
`[57]
`An inflatable protective system provides cushioning
`and containment of an occupant of a vehicle from side
`impact of the vehicle by another object. The system
`includes an inflatable bag which is foldabble into a col(cid:173)
`lapsed, relatively compact configuration for placement
`within a door of a vehicle. An inflator and an impact
`sensor are also mounted within the door, with the infla(cid:173)
`tor being in flow communication with the bag. Upon
`impact of the door, the sensor activates the inflator to
`inflate the bag. The inflated bag forms a substantially
`broad, planar air cushion having dimensions sufficient
`to extend over the window opening in the door. The
`inflated bag forms a shock absorbing cushion that pre(cid:173)
`vents the occupant's head from striking the door ele(cid:173)
`ments and also acts as a cushioning barrier to restrain
`the occupant's head from being ejected through the
`window opening.
`
`26 Claims, 6 Drawing Sheets
`
`28
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`52
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`U.S. Patent Oct. 30, 1990
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`U.S. Patent
`US. Patent
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`Oct. 30, 1990
`Oct. 30, 1990
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`Sheet 2 of 6
`Sheet 2 of 6
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`4,966,388
`4,966,388
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`U.S. Patent
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`Oct. 30, 1990
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`Sheet 3 of 6
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`4,966,388
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`FIG. 4
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`FIG. 5
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`41
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`U.S. Patent
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`Oct. 30, 1990
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`Sheet 4of6
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`U.S. Patent Oct. 30, 1990
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`Sheet 5of6
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`4,966,388
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`FIG. 8
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`41
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`Fl G. 9
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`41
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`42
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`FIG. 10
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`Fl G. 14
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`FI G.
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`II
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`U.S. Patent
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`Oct. 30, 1990
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`Sheet 6 of 6
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`4,966,388
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`FIG. 12
`;::-27
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`FIG. 13
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`42
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`43
`r
`14
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`28
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`44
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`14
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`28
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`FIG. 15
`59 /32
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`28
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`31
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`1
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`4,966,388
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`INFLATABLE STRUCTURES FOR SIDE IMPACT
`CRASH PROTECTION
`
`BACKGROUND OF THE INVENTION
`1. Field of the Invention
`The present invention relates to inflatable restraint
`devices used in automotive vehicles for restraining
`movement of an occupant and cushioning contact be(cid:173)
`tween the occupant and structural members of the vehi- 10
`cle during an accident. In particular, the invention re(cid:173)
`lates to such restraint devices which are contained in a
`side panel of the vehicle and which provide protection
`from side impacts of the vehicle.
`2. State of the Art
`Inflatable restraint devices for restraining occupants
`of automotive vehicles involved in frontal collisions are
`of course well known. Such systems employ air bags
`which are inflated rapidly in response to a collision,
`with the inflated air bags providing a cushioning and 20
`restraint for the occupants from impact with the steer(cid:173)
`ing wheel, instrument panel and windshield of the vehi(cid:173)
`cle. For examples of such systems see U.S. Pat. Nos.
`3,642,303; 3,758,133 and 4,097,065.
`The inflatable restraint systems of the prior art gener- 25
`ally do little to provide essential protection to an occu(cid:173)
`pant of a vehicle during accidents involving impact of
`the side of the vehicle. During side impact collisions,
`seat belts do little more than prevent occupants from
`impacting each other and prevent total ejection of an 30
`occupant from the vehicle. In a side impact collision the
`occupant is subject to dangerous contact with the side
`of the vehicle next to which the occupant is seated and
`the distinct possibility exists of partial ejection of and
`injury to the occupant's head, neck and shoulders 35
`through the window area of that side of the vehicle.
`Conventional restraint systems have not adequately
`addressed these problems.
`Some limited protection in side impact collisions is
`afforded by conventional padding applied to the inte- 40
`rior surfaces of the side panel, but space and comfort
`limitations along the interior of the side panel preclude
`use of sufficient padding depth to be of significant value
`in a moderate-to-severe accident. In U.S. Pat. No.
`3,791,667, it was proposed to provide a housing re- 45
`cessed in a side panel of a vehicle, with the housing
`having an open side facing the interior of the vehicle.
`An elastomeric, stretchable membrane was secured
`over the open side of the housing, having its peripheral
`edges sealed to the housing. In a collision, gas under 50
`pressure was delivered to the housing to expand the
`membrane toward the interior of the vehicle to form a
`cushion for the torso of an occupant seated adjacent
`thereto. The system of U.S. Pat. No. 3,791,667 does not,
`however, provide any cushioning of the occupants' 55
`shoulders and head from impact with a window in the
`side panel, the window frame, the roof pillar adjacent
`the side of the window or the roof rail adjacent the
`upper side of the window. Nor does such system offer
`any restraint against the occupant's head and neck from 60
`being thrown through the window.
`In U.S. Pat. No. 3,897,961, inflatable restraint appara(cid:173)
`tus is disclosed which include folded air bags stored in
`the roof structure of the vehicle. A torso bag is de(cid:173)
`ployed from the roof of the vehicle toward the lap of 65
`the occupant. In addition, an inflatable side curtain bag
`is deployed from the roof to, at least theoretically, ex(cid:173)
`tend downward between the occupant and a side win-
`
`2
`dow in the side panel of the vehicle. If properly inflated
`and positioned, the side curtain would provide side
`cushioning of the head and shoulders of the occupant
`and inhibit movement of the occupant's head through
`the window or against the roof rail. Unfortunately,
`however, the source of gas for inflating both the torso
`bag and the curtain bag is located out of the passenger
`compartment, and a conduit extends from the gas
`source to the respective air bags.
`To be effective in side impact collisions, a restraint
`system must offer essentially immediate padding and
`restraint to the entire flank of the occupant. Timing of
`air bag deployment is absolutely critical. In a typical
`crash, each millisecond delay represents about one-half
`15 inch of side panel or door penetration. The system of
`U.S. Pat. No. 3,897,961 has not been used commercially,
`and it is likely that delays in activating the gas generator
`and then of transmitting the gas to the air bags would be
`far too long for the system to work effectively. In addi(cid:173)
`tion, the system is bulky, relatively complex and would
`be excessively costly.
`An even more complex system is disclosed in U.S.
`Pat. No. 3,687,485. An air bag is deployed downwardly
`from the roof structure of the vehicle toward the rear
`seat thereof. A series of pulleys and cables are provided
`for pulling a screen downwardly over the side window
`of the vehicle as the air bag is deployed. The system of
`Pat. No. 3,687,485 has not been used commercially
`possibly due to its excessive complexity or its potential
`to iflict injury during deployment.
`SUMMARY OF THE INVENTION
`A principal objective of the invention is to provide a
`novel, relatively inexpensive, air bag, restraint system
`which is located within the side panel of an automotive
`vehicle so as to preserve roominess and comfort space
`within the vehicle, with the system being simple in
`mechanical construction and operation yet highly effec(cid:173)
`tive in affording protection to an occupant seated adja(cid:173)
`cent to the side panel of the vehicle during a collision
`involving impact of that side panel of the vehicle with
`another object.
`A particular objective of the present invention is to
`provide such an air bag restraint system which can be
`deployed relatively instantaneously from the side panel
`of the vehicle to offer essentially immediate padding
`and restraint for the entire flank of the occupant seated
`adjacent to such side panel.
`Another objective of the present invention is to pro(cid:173)
`vide an air bag system of the type described wherein
`protection is afforded essentially instantaneously to the
`flank of the occupant, with the system simultaneously
`providing a cushioning barrier to restrain the occu(cid:173)
`pant's head and neck from moving into the window or
`window opening in the side panel as well as from con(cid:173)
`tacting the window frame, roof pillar or roof rail of the
`side panel.
`Another objective of the present invention is to pro(cid:173)
`vide such an air bag restraint system wherein the cush(cid:173)
`ioning barrier further restrains the occupant's head
`from moving through the window or window frame to
`thereby avoid severe injury which could otherwise be
`incurred through contact with an object outside the
`window of the vehicle.
`Yet another objective of the present invention is to
`provide an air bag system of the type described wherein
`a cushioning panel made of resilient, foamed, polymeric
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`3
`material is provided as the inboard face of the side
`panel, and when the air bag is inflated, the cushioning
`panel is propelled toward the occupant to provide im(cid:173)
`mediate cushioning contact with the occupant's torso
`and to initiate lateral movement of the occupant away S
`from the side panel so as to minimize the subsequent
`impact between the side panel and the occupant.
`A further objective of the present invention is to
`provide an air bag system of the type described wherein
`the system includes a highly reliable sensor mechanism 10
`housed within the side panel of the vehicle together
`with the air bag and gas generating means, with the
`sensor mechanism being mechanically simple, relatively
`inexpensive, and capable of faithfully sensing an impact
`to the side panel of the vehicle of a specified severity, IS
`while avoiding undesirable, false deployment of the air
`bag due to normal vehicle usage or to impacts of less
`severity.
`A still further objective of the present invention is to
`provide an air bag system of the type described wherein 20
`voids in the side panel of the vehicle are filled with a
`resilient, foamed, polymeric material to increase cush(cid:173)
`ioning, hasten early displacement of the occupant in a
`direction away from the object impacting the side panel ZS
`of the vehicle and dissipate force by crushing of the
`foamed material by the object impacting the side panel.
`Another objective of the present invention is to pro(cid:173)
`vide an air bag restraint system in which the air bag is
`mounted, in the uninflated, standby state, entirely 30
`within the side panel of a automotive vehicle, with the
`uninflated bag being folded and stored in a compart(cid:173)
`ment within the side panel such that upon external im(cid:173)
`pact with the exterior side of the panel, the air bag
`initially inflates inwardly toward the torso of an occu- 3s
`pant seated adjacent to the side of panel and then con(cid:173)
`tinues to inflate both inwardly and upwardly along the
`interior of the side panel to rapidly cover a window in
`the upper portion of the side panel, all within a matter of
`several milliseconds.
`An additional objective of the present invention is to
`provide such an air bag system wherein a plurality of
`vent openings are activated in sequence as the air bag is
`inflated to provide controlled venting of gas to moder(cid:173)
`ate peak pressures within the inflating air bag and to 4S
`further develop thrust from the venting gases to en(cid:173)
`hance deployment of the air bag upwardly along the
`interior of the side panel of the vehicle.
`The above objectives are achieved in accordance
`with the present invention by providing a novel air bag so
`restraint system which is contained, in its uninflated,
`standby state, entirely within a side panel of an automo(cid:173)
`tive vehicle. By being contained within the side panel,
`the present system has the advantage of preserving
`roominess in the vehicle.
`The system of the present invention incorporates an
`inflatable air bag and padding to provide protection
`from side impact collisions with the vehicle. A folded
`air bag and an associated inflator, which is capable of
`inflating the air bag, are contained in a compartment 60
`within the side panel of the vehicle. A sensor mecha(cid:173)
`nism which is adapted to activate the inflator is prefera(cid:173)
`bly positioned within the side panel. A strategically
`located, remote sensor can be used, especially in combi(cid:173)
`nation with the local sensor positioned within the side 6S
`panel. The system further includes a finish cover for the
`side panel which forms the inner, finished face of the
`side panel. The cover is preferably formed from a sub-
`
`ss
`
`40
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`4,966,388
`
`4
`stantially planar panel made of resilient foamed poly(cid:173)
`meric material.
`Upon impact of the side of the vehicle with another
`object, with sufficient force to be sensed by the sensor,
`the inflator is activated to inflate the air bag. During the
`initial inflation stage, the air bag inflates toward the
`torso of the occupant. The foamed planar cushioning
`panel forming the internal face of the side panel is pro(cid:173)
`pelled ahead of the inflating bag toward the torso of the
`occupant. The expanding bag and the foamed cushion(cid:173)
`ing panel make cushioned contact with the occupant's
`torso and produce early lateral movement of the occu(cid:173)
`pant away from the side panel and the intruding object
`which has collided with occupant's vehicle. This early
`movement of the occupant reduces the force of the
`inevitable impact which follows between the occupant
`and the side panel and object intruding into the side
`panel.
`The initial deployment of the air bag is followed with
`an upward inflation of the bag along the interior side of
`the side panel. The air bag when fully inflated has a
`generally planar, broad shape designed to cover the
`relatively large shoulder and head contact areas of the
`occupant. The inflated air bag expands fore and aft of
`the side panel as well as upwardly so as to cover the
`upper portion of the side panel and in particular any
`window, roof pillar and roof rail in the vicinity of the
`occupant's head. The inflated air bag barrier restrains
`the occupant's head, neck and shoulders from moving
`into the window or window opening, thereby prevent(cid:173)
`ing partial or total ejection of the occupant's head from
`the vehicle. The air bag also restrains the occupant's
`head from striking the window, window frame, roof
`pillars adjacent to the sides of the window and the roof
`rail adjacent to the top of the window.
`Additional objects and features of the invention will
`become apparent from the following detailed descrip(cid:173)
`tion, taken together with the accompanying drawings.
`
`THE DRAWINGS
`A preferred embodiment of an air bag restraint sys(cid:173)
`tem in accordance with the present invention represent(cid:173)
`ing the best mode presently contemplated of carrying
`out the invention are illustrated in the accompanying
`drawings in which:
`FIG. 1 is an exploded, pictorial representation of a
`door of a vehicle containing the air bag restraint system
`of the present invention;
`FIG. 2 is a simplified, diagramatical section through
`the door panel of FIG. 1 showing the door incorporated
`into a vehicle, with an occupant seated next to the door;
`FIG. 3 is a view similar to that of FIG. 2 but showing
`the air bag in its inflated, expanded condition;
`FIG. 4 is a simplified, diagramatical, side view of the
`occupant and the inside of the door of FIG. 2;
`FIG. 5 is a view similar to that of FIG. 4 but showing
`the air bag in its inflated, expanded condition;
`FIG. 6 is a side view of an inflated, expanded air bag
`in accordance with the present invention showing the
`side of the bag which faces the door panel;
`FIG. 7 is a view similar to that of FIG. 6 but showing
`the opposite side of the bag, that is the side facing the
`occupant;
`FIG. 8 shows a flat air bag in accordance with the
`present invention in the first stage of folding the bag
`into a planar pouch to be placed within the door of FIG.
`1;
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`FIG. 9 is a view similar to that of FIG. 8 but showing
`the bag in the second stage of folding;
`FIG. 10 is a view similar to that of FIGS. 8 and 9 but
`showing the bag in the third stage of folding;
`FIG. 11 is a view similar to that of FIGS. 8, 9 and 10 s
`but showing the bag in the final stage of folding into the
`planar pouch;
`FIG. 12 is a vertical section through the folded air
`bag module of FIG. 1;
`FIG. 13 is a view similar to that of FIG. 12 but show- 10
`ing the air bag in its inflated, expanded condition;
`FIG. 14 is a section taken along line 14--14 of FIG.
`13; and
`FIG. 15 is an exploded pictorial view of one embodi(cid:173)
`ment of a strip switch sensor-activator used in the in- 15
`vention.
`DETAILED DESCRIPTION OF THE
`ILLUSTRATED EMBODIMENT
`Referring to the drawings, an inflatable protective 20
`system is shown which provides cushioning and con(cid:173)
`tainment of an occupant of a vehicle from a collision
`involving side impact of the occupant's vehicle with
`another object such as another vehicle. As illustrated,
`the occupant's vehicle, is a conventional automobile 25
`having a side panel 20 located adjacent to the end of a
`seat 21 upon which the occupant to be protected is
`seated. The side panel 20, as illustrated, is a side door of
`the automobile and will be referred hereinafter as a door
`panel. It should be recognized, however, that the inven- 30
`tion is applicable to a side panel of an automotive vehi(cid:173)
`cle generally and is not restricted to a door panel or to
`any particular type vehicle. For instance, the invention
`could be applied to the side panels adjacent to the back
`seat of a conventional two door automobile, as well as 35
`doors and side panels of trucks. In the illustrated em(cid:173)
`bodiment, a window 22 and appropriate window frame
`23 are located at the upper end of the door panel 20. A
`roof pillar 24 is located adjacent to a vertical side of the
`window 22, and a roof rail 25 is positioned adjacent to 40
`an upper side of the window 22.
`The restraint system of the present invention includes
`an inflatable bag 27 which can be folded into a col(cid:173)
`lapsed, relatively compact configuration. A detailed
`description of one preferred procedure used in folding 45
`the bag 27 will be given later herein. Bag 27 is adapted
`to be inflated to form a substantially broad, planar air
`cushion as shown in FIGS. 3 and 5, with the dimensions
`of the inflated bag 27 being sufficient to extend substan(cid:173)
`tially over the window 22 in the door panel 20 as shown SO
`in FIG. 5.
`The folded bag 27 is mounted and stored within the
`door panel 20 at a location below the window 22, with
`the folded bag 27 facing the occupant's torso when the
`occupant is seated on the seat 21. An inflator 30 is 55
`mounted within the door panel 20 and in flow commu(cid:173)
`nication with the folded bag 27. An impact sensor 32 is
`also mounted within the door panel 20. One or more
`similar sensors, and possibly a system of microswitches,
`can be located adjacent to the first sensor or at strategi- 60
`cally located, remote positions. The sensors 32 are capa(cid:173)
`ble of activating the inflator 30 to inflate the bag 27
`when an impact of a specified severity is made with
`another object, such as another vehicle, and the door
`panel 20. The inflated bag 27 forms a shock absorbing 65
`cushion for the head and flank of the torso of the occu(cid:173)
`pant and a cushioning barrier to restrain the occupant's
`head, neck and shoulders from moving toward or
`
`6
`through the window 22 or of engaging the roof pillar
`24, window frame 23 and roof rail 25.
`The folded bag 27 is mounted in a cavity 29 (FIGS. 2,
`3 and 4) formed within the door panel 20 of the vehicle.
`Preferably, an air bag module is provided for insertion
`into the cavity 29. The air bag module is shown in FIG.
`1, 10, 12 and 13. The module includes a rigid backup
`plate 28 which is to be positioned at the inner side of the
`cavity 29. The inflatable bag 27 is folded into a substan(cid:173)
`tially planar pouch which is positioned within the cav(cid:173)
`ity 29 adjacent to the backup plate 28. The module
`further includes the inflator means 30, which is mounted
`to the backup plate 28 so as to be in direct flow commu(cid:173)
`nication with the folded air bag 27. The inflator 30 is
`advantageously mounted on one side of the backup
`plate 28 and communicates with the bag 27 through an
`access opening 31 in the backup plate 28. An exhaust
`port 33 of the inflator 30 is coupled directly to an access
`opening in the bag 27. The inflator 30 is preferably a
`pyrotechnic inflator which is commercially available
`for use in inflating air bags in the automobile industry.
`As shown in FIGS. 3 and 13, the air bag 27 comprises
`two sections, with the first section 37 being attached to
`the inflator 30. Section 37 is the first to inflate when the
`bag 27 is inflated and is adapted to expand substantially
`instantaneously toward the interior of the vehicle from
`the cavity 29. As the inflation of the bag 27 continues,
`the second section 38 extends from the upper side of the
`first section 37 and expands upwardly over the window
`22 in the door panel 20, as best shown in FIGS. 3 and 5.
`Complete inflation of both sections 37 and 38 of the bag
`27 is extremely rapid, occurring in about 30 to 50 milli(cid:173)
`seconds.
`The bag 27, when inflated, preferably has fore and aft
`extensions 41 as shown in FIGS. 5, 6 and 7. The exten(cid:173)
`sions 41 fan out from a central portion of the bag 27
`during inflation to extend to the fore and aft sides of the
`window 22. The fan shaped extensions 41 allow the first
`section 37 of the bag 27 to have a much smaller lateral
`dimensions than that of the second section 38 and the
`window 22. The smaller size of the first section 37 with
`respect to the second section 38 accommodates the
`substantially instantaneous inflation of the first section
`37, the benefit of which will be more fully described
`hereinafter.
`For storage in the cavity 29, the bag 27 is preferably
`folded into a substantially planar pouch. A sample fold(cid:173)
`ing technique is shown in FIGS. 1 and 8 through 12.
`The pouch can be formed by folding the upper portion
`of the bag 27 downwardly in at least two accordion
`folds to overlie the lower portion of the bag 27. The
`resulting, planar pouch is then inserted into the cavity
`29 so that the folded upper portion of the bag 27 faces
`the interior of the vehicle. A preferred technique for
`folding the bag 27 is illustrated in FIGS. 8 through 12.
`First, the fore and aft sections 41 are folded inwardly as
`shown in FIG. 8 so as to lie over or be nested inside the
`central, generally rectangular portion of the bag 27.
`The upper about one-third portion of the generally
`rectangular formation is then folded backwardly as
`shown in FIG. 9 to lie behind the central about one(cid:173)
`third portion of the bag 27. The upper and central por(cid:173)
`tions are then folded forwardly about the bottom edge
`of the central portion so as to overlie the front of the
`lower about one-third portion of the bag 27 as shown in
`FIG. 10. A final S-shaped fold can be formed in the free
`upper edge of the upper portion of the bag 27 if desired,
`as shown in FIG. 11.
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`As shown in FIGS. 13 and 14, the bag 27 comprises
`two broad sheets 42 of material which, when the bag 27
`is inflated, face each other and form outboard and in(cid:173)
`board sides of the inflated bag 27. The outboard side of
`the inflated bag 27 lies adjacent to the door panel 20 and
`faces the window 22 thereof, and the inboard side of the
`bag 27 faces the interior of the vehicle. To maintain
`strength as well as the generally flat shape of the upper
`section 38 of the inflated bag 27, the two sheets of mate(cid:173)
`rial 42 forming the upper section 38 are stitched to- 10
`gether with reinforcing stitching 43 which attaches
`spaced linear ribs or tethers radiating outwardly from
`the first section 37 of the bag 27. Advantageously, as
`shown in FIGS. 13 and 14, the air bag 27 is reinforced
`with fabric webs 44 which form part of the ribs. The 15
`webs 44 extend from one of the side sheets 42 of the bag
`27 to the other. The opposite lateral sides of the webs 44
`are sewn to the side sheets 42 by the stitching 43. The
`webs 44 aid in maintaining proper thickness of the air
`bag 27 when it is inflated as well as to reinforce and add 20
`strength to the bag 27.
`A plurality of vent openings 46 are preferably pro(cid:173)
`vided in the outboard side of the upper or second sec(cid:173)
`tion 38 of the bag 27 as shown in FIG. 6. The vent
`openings 46 are spaced apart over the side of the bag 27 25
`and allow controlled venting of gas during inflation of
`the bag 27 to moderate pressure peaks within the bag
`during inflation. The openings 46 also provide jet thrust
`to the inflating bag 27 to enhance deployment of the bag
`adjacent to the window 22 of the door panel 20. Prefer- 30
`ably, at least one vent opening 46 is also provided in the
`lower or first section 37 of the bag 27. The openings 46
`in the lower section 37 of the bag 27 primarily aid in
`controlling venting of gas during inflation of the bag 27
`to moderate pressure peaks within that portion of the 35
`bag during inflation.
`One of the important functions of the air bag 27 of the
`present invention is to form a barrier for preventing the
`occupant's head, neck and shoulders from impacting the
`window frame 23, roof pillar 24 and roof rail 25, as well 40
`as to stop the occupant's head and neck from being
`ejected through the window 22 where serious contact
`could be made with objects on the outside of the vehi(cid:173)
`cle. The air bag 27 inflates so as to cover the window
`area and thus form the barrier. To aid in holding the 45
`barrier firmly in place during the accident, touch at(cid:173)
`tachment means are provided on the periphery of the
`second section 38 of the bag 27 and on the roof rail 25
`and roof pillar 24 which are adjacent to the window 22
`of the door panel 20. The touch attachment means se- 50
`cure the periphery of the second section 38 of the bag 27
`to the roof rail 25 and roof pillar 24 when the bag 27 is
`inflated to firmly hold the inflated bag 27 in place as a
`barrier over the window 22. As shown in FIGS. 4 and
`7, the touch attachment means preferably comprises 55
`two part releasable connectors of the hook and loop
`type. A representative type hook and loop connector is
`marketed under the trademark Velcro. One part 47 of
`the connectors is attached about the periphery of the
`second section 38 of the bag 27, and the second part 48 60
`of the connectors is attached along the roof rail 25 and
`roof pillar 24. As illustrated, a continuous strip of the
`part 48 of the connector extends along the roof pillar 24
`and roof rail 25. Elongate patches of the other part 47 of
`the connector are sewn to the air bag 27 as shown in 65
`FIG. 7. The elongate patches are spaced about the
`upper perimeter of the bag 27, with the patches extend(cid:173)
`ing inwardly toward the central portion of the bag 27.
`
`8
`The air bag 27 cooperates with strategically posi(cid:173)
`tioned foam cushioning material to provide exceptional
`load distribution and acceleration peak-shaving to the
`occupant during a side impact collision. A substantially
`planar cushioning panel 50 of foamed polymeric mate(cid:173)
`rial is positioned on the inboard side of the door panel
`20, such that the cushioning panel 50 lies over the
`stored, folded bag in the cavity 29 of the door panel 20.
`A finish formed on the outer surface of the cushioning
`panel 50 forms the finished inboard side of the door
`panel 20. The cushioning panel 50 is preferably made of
`a foamed polymeric material such as polyethylene hav(cid:173)
`ing 20 psi crush resistance. The panel 50 is generally
`from about one inch to three inches thick, preferably
`about two inches. Upon collision and inflation of the air
`bag 27, the cushioning panel 50 is propelled inwardly
`toward the occupant to make initial cushioned contact
`with the occupant's torso and to initiate lateral move(cid:173)
`ment of the occupant away from the door panel 20.
`Such movement of the occupant will minimize the rela(cid:173)
`tive speed at which the door panel 20 of the automobile
`makes contact with the occupant during the collision.
`As best shown in FIG. 1, the cushioning panel 50 is
`formed of a first section 51 which lies immediately over
`the cavity 29 in the door panel 20 and a second section
`which lies over the remainder of the door panel 20
`below the window 22. The first section 51 is attached to
`the second section 52 by a hinge connecting the lower
`edge of the first section 51 to the second section 52, such
`that when the bag 27 is inflated, the first section 51 of
`the cushioning panel 50 pivots about its lower hinged
`edge to form an opening through which the inflating
`bag 27 is rapidly ejected outwardly and upwardly from
`the cavity 29. The inflating bag 27, at the same time,
`propels the cushioning panel 50 laterally toward the
`occupant. The hinge is preferably a live hinge formed
`by a skin of the foamed polymer material which inte(cid:173)
`grally joins the first and second sections 51and52 of the
`cushioning panel 50.
`It can now be appreciated why it is important to
`achieve an almost instantaneous inflation of the lower
`section 37 of the air bag 27 prior to the inflation of the
`upper section 38 as mentioned above. The rapid infla(cid:173)
`tion of the lower section 37 provides rapid movement of
`the cushioning panel 50 toward the occupant such that
`the cushioning panel comes into contact with the occu(cid:173)
`pant before the door panel 20, propelled inward by the
`impacting object, makes contact with the occupant.
`The cushioning panel distributes forces over the torso
`of the occupant and further moves the occupant in a
`direction away from the door panel. This movement of
`the occupant reduces the relative speed with which the
`door panel subsequently impacts the occupant. In addi(cid:173)
`tion, the displacement of the cushioning panel 50 away
`from the door panel 20 provides sufficient space for the
`upper section 38 of the bag 27 to inflate upwardly to its
`operative position in which it provides protection to the
`upper torso and head of the occupant.
`To provide additional cushioning and padding, and to
`enhance the promptness of occupant-load applications,
`all otherwise void space between the outboard side and
`inboard side of the door panel 20 is preferably filled
`with foamed polymeric material. As shown in the draw(cid:173)
`ing, slabs 54 of rigid foamed material can be cut and
`fitted into void spaces in the door panel 20. In a produc(cid:173)
`tion vehicle, this cushioning material would likely be
`molded to fit in the void spaces. The cavity 29 is advan-
`
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`4,966,388
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`9
`tageously formed in this cushioning material such that
`the cushioning material supports the air bag module.
`In side impact collisions, the inflation of the air bag 27
`must be extremely rapid. There must be a minimal delay
`between the impact and the actuation of the inflator 30.
`In the present design, the inflator 30 has been positioned
`in direct fluid communication with the air bag 27 to
`achieve ultra-rapid inflation once the inflator 30 has
`been activated. The sensor system must be reliable and
`not subject to false alarms. Above all it must instanta- 10
`neousl