Method to manufacture airbag mini packs

Patent metadata

Field	Value
Publication number	US-10328891-B2
Application number	US-201515520869-A
Country	US
Kind code	B2
Filing date	Oct 27, 2015
Priority date	Oct 27, 2014
Publication date	Jun 25, 2019
Grant date	Jun 25, 2019

Abstract

A method of forming an airbag cushion ( 10, 10 A) has the steps of providing placing the cushion in a vacuum bag ( 20 ) and evacuating the air shrinking the airbag cushion ( 10, 10 A) to a compacted size; conforming the airbag cushion to a predetermined shape; placing the airbag cushion ( 10, 10 A) in a high temperature environment between +50° C. to +140° for a predetermined time to thermally set the fabric material ( 120 ) to maintain the compacted airbag cushion ( 10, 10 A) to the predetermined shape; and releasing the vacuum and removing the thermally set airbag cushion ( 10, 10 A) from the vacuum bag ( 20 ).

First claim

What is claimed is:

1. A method of forming a folded airbag cushion ( 10 , 10 A) comprises the steps of:
providing an airbag cushion made of fabric material ( 12 );
placing the cushion ( 10 , 10 A) in a vacuum bag ( 20 ) and evacuating the air to create a vacuum and shrinking the airbag cushion to a compacted size;
providing a shape forming contoured surface ( 102 a ) of a mandrel ( 102 ) against or within which the airbag cushion ( 10 , 10 A) is positioned on the mandrel and draped over the contoured surface ( 102 a ) of the mandrel to be drawn tightly over the contoured surface ( 102 a ) of the mandrel ( 102 ) to follow the contour during the step of creating a vacuum and presetting the cushion at a temperature up to 200° C. to set the cushion fabric material ( 12 ) to take the contour of the mandrel ( 102 );
placing the airbag cushion ( 10 , 10 A) in a high temperature environment between +50° C. to +140° C. for a predetermined time to thermally set the fabric material ( 12 ) to maintain the compacted airbag cushion shape; and
releasing the vacuum and removing the thermally set airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ), the cushion maintaining the predetermined shape being formed as a mini pack or compacted airbag cushion ( 10 , 10 A).

2. The method of claim 1 wherein the predetermined time to thermally set the material ( 12 ) is up to 2 hours.

3. The method of claim 1 further comprises the step of:
applying a compressive load or force on the evacuated airbag cushion ( 10 , 10 A) prior to the step of thermally setting the fabric material ( 12 ) and removing the compression force prior to removing the airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ).

4. The method of claim 1 further comprises the step of:
folding the airbag cushion ( 10 , 10 A) prior to placing it in the vacuum bag ( 20 ).

5. A method of forming a folded airbag cushion ( 10 , 10 A) comprises the steps of:
providing an airbag cushion made of fabric material ( 12 );
inserting a simulator of an inflator ( 40 ) in the cushion ( 10 , 10 A) to mimic the shape of an inflator ( 40 ), the simulator providing a contour surface for the airbag, the airbag cushion being folded with the simulator inside;
placing the folded cushion ( 10 , 10 A) with the simulator in a vacuum bag ( 20 ) and evacuating the air to create a vacuum and shrinking the airbag cushion to a compacted size;
providing a shape forming contoured surface ( 102 a ) of a mandrel ( 102 ) against or within which the airbag cushion ( 10 , 10 A) is positioned on the mandrel and draped over the contoured surface ( 102 a ) of the mandrel to be drawn tightly over the contoured surface ( 102 a ) of the mandrel ( 102 ) to follow the contour during the step of creating a vacuum and presetting the cushion at a temperature up to 200° C. to set the cushion fabric material ( 12 ) to take the contour of the mandrel ( 102 );
placing the airbag cushion ( 10 , 10 A) in a high temperature environment at 85° C. for 1.5 hours to thermally set the fabric material ( 12 ) to maintain the compacted airbag cushion shape;
releasing the vacuum and cooling the cushion and removing the thermally set airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ), after cooling removing the simulator and replacing the simulator with a live inflator, the cushion maintaining the predetermined shape being formed as a mini pack or compacted airbag cushion ( 10 , 10 A).

6. The method of claim 1 further comprises the step of:
assembling the airbag cushion ( 10 , 10 A) about a curtain airbag fixture, dire or mandrel prior to the step of evacuation.

7. The method of claim 1 further comprises the step of:
placing the formed airbag cushion ( 10 , 10 A) in an airbag module housing ( 30 ) to form a module assembly.

8. The method of claim 1 wherein the relaxed folded airbag cushion ( 10 , 10 A) retains a size reduction in thickness in the range of 20% to 40% smaller compared to the same cushion folded but not processed using the method of claim 1 .

9. A compacted airbag cushion ( 10 , 10 A) made by the method of claim 1 .

10. A compacted airbag cushion ( 10 , 10 A) of claim 9 further comprising a module housing for storing the mini pack airbag cushion ( 10 , 10 A).

Assignees

• Key Safety Systems Inc

Inventors

• Volkmann Matthias
• Pieruch Martin

Classifications

• B60R21/235

  characterised by their material · CPC title

• B29C43/12

  using bags surrounding the moulding material {or using membranes contacting the moulding material} · CPC title

• B60R21/20

  Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components · CPC title

• B60R2021/23509

  Fabric · CPC title

• B60R2021/2375

  Folding devices · CPC title