Vehicular airbag apparatus

The present invention relates to a vehicular airbag apparatus, and particularly to a vehicular airbag apparatus of a type in which part of an airbag is retained between a portion of a retainer case and a diffuser in the retainer case.

This type of vehicular airbag apparatus has been disclosed in Japanese Patent Application Laid-Open Publication No. 10-273005.

In this conventional art, an internal space of a retainer case is partitioned by a diffuser into a gas diffusion chamber for an inflator to be disposed therein, and an accommodation chamber for accommodation of an airbag, with gas communication allowed therebetween through an opening of the diffuser. This arrangement provides a compact apparatus.

In the conventional art, however, a part of the airbag retained between a portion of the retainer case and the diffuser confronts the gas diffusion chamber, with a fear of receiving undue thermal effects of hot gases discharged from the inflator.

The present invention is made with such points in view. It therefore is an object of the present invention to provide a vehicular airbag apparatus in which a retained part of an airbag is substantially free from undue effects of hot gases.

To achieve the object, according to an aspect of the present invention, there is provided a vehicular airbag apparatus comprising: a retainer case having a first portion defining a gas diffusion chamber, a second portion defining a accommodation chamber, and a third portion between the first and second portion; a diffuser member separating the gas diffusion chamber from the accommodation chamber, with gas communication allowed therebetween through an opening of the diffuser member; and inflator disposed in the gas diffusion chamber; and airbag accommodated in the accommodation chamber, the airbag having a retained part thereof between the third portion of the retainer case and the diffuser member; and a gas invasion restrictor configured to restrict a gas invasion into between the third portion of the retainer case and the diffuser member.

The above and further objects and novel features of the present invention will more fully appear from the following detailed description when the same is read in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of an instrument panel having a vehicular airbag apparatus according to an embodiment of the invention;

FIG. 2 is a perspective view of a retainer case of the vehicular airbag apparatus in the instrument panel of FIG. 1;

FIG. 3 is a sectional view along line III—III of FIG. 1;

FIG. 4 is a detailed section of part IV of FIG. 3;

FIG. 5 is a sectional view along line V—V of FIG. 3;

FIG. 6 is a sectional view of a corresponding part to FIG. 4 in an airbag apparatus according to another embodiment of the invention; and

FIG. 7 is a sectional view of a corresponding part to FIG. 4 in an airbag apparatus according to another embodiment of the invention.

There will be detailed below the preferred embodiments of the present invention with reference to the accompanying drawings. Like members are designated by like reference characters.

First Embodiment

Description is now made of a first embodiment of the invention, with reference to FIG. 1 to FIG. 5 . In FIG. 1, designated by reference character 1 is an instrument panel vehicle-transversely extending at a front of a vehicular occupant room. The instrument panel 1 has at the navigator side (left side in FIG. 1) a rectangular opening 2 formed in the upside, and a lid member 3 fitted in the opening 2 . As best shown in FIG. 3, the lid member 3 is constituted with a flat lid portion 3 a which is fixed to a periphery 2 a of the opening 2 , and a rectangular guide wall portion 3 b which extends obliquely downward from downside of the lid portion 3 a . The lid portion 3 a has a cut 3 c at the backside, to be torn therealong in an H-form as indicated by dot lines in FIG. 1, so as to upwardly open, when pushed from below by an inflated airbag.

Below the opening 2 is provided an airbag-device-retaining casing (called “retainer case”) 4 of a metallic panel structure, which is fixed in a rearward inclined position. The retainer case 4 has: an inflator-accommodating lower portion 4 a (FIG. 2, FIG. 3, FIG. 4, FIG. 5) which defines a vehicle-transversely extending substantially cylindrical accommodation chamber (called “gas diffusion chamber”) 5 (FIG. 3, FIG. 4, FIG. 5) that is open along an upper arcuate region 5 a indicated by one-dot chain line (FIG. 3) and close at both axial ends with end plates 5 b (FIG. 2, FIG. 5) of which either is removable by detachment of a stopper 5 c (FIG. 2, FIG. 5 ); an airbag-retaining intermediate portion 4 b (FIG. 2, FIG. 3, FIG. 4, FIG. 5) which is obliquely upwardly spread to be configured in a vehicle-transversely elongate rectangular funnel form that is continuous at the lower edge to a periphery 5 d (FIG. 3, FIG. 4) of the upper arcuate region 5 a of the gas diffusion chamber 5 ; and an airbag-enclosing upper portion 4 c (FIG. 2, FIG. 3, FIG. 5) which is cooperative with the intermediate portion 4 b to define a vehicle-transversely extending irregular-six-side-prismatic accommodation chamber (called “bag accommodation chamber”) 6 (FIG. 2, FIG. 3, FIG. 5) that is open at both upper and lower sides and close at both axial ends with end plates 6 a (FIG. 2 ). The upper portion 4 c itself of the retainer case 4 is shaped in the form of a rectangular box open upward, as a guide wall congruent in section to and continuously opposing the guide wall portion 3 b of the lid member 3 . The upper portion 4 c is constituted as a removable separate member, but normally is fixed relative to the intermediate part 4 b which is integrated with the lower portion 4 a.

The retainer case 4 is mounted as a whole to an unshown strong rigid member of the vehicle body, for example to a steering member, by using fixtures such as left and right three-leg brackets 7 (FIG. 2, FIG. 3, FIG. 5) each respectively attached to outsides of lower front and rear parts 4 d and 4 e (FIG. 2, FIG. 3, FIG. 5) of the lower portion 4 a of the retainer case 4 in which the gas diffusion chamber 5 is defined.

In the bag accommodation chamber 6 is accommodated an airbag 8 (FIG. 3, FIG. 4, FIG. 5) in a folded condition. The upper portion 4 c of the retainer case 4 defining the bag accommodation chamber 6 is wholly covered with a thin cover 10 put thereon for protection against invasion such as of dust. The cover 10 can be torn at a top part 10 a thereof by the airbag 8 when this is inflated. Front and rear side parts 10 b (FIG. 3) of the cover 10 are applied over raised fixtures 9 a (FIG. 2, FIG. 3) provided on the upper portion 4 c of the retainer case 4 , to tense the top part 10 a . Lower end parts 10 c of the cover 10 are engaged with hooks 9 b (FIG. 3, FIG. 5) provided on four sides of the upper portion 4 c of the retainer case 4 .

In the gas diffusion chamber 5 is installed a vehicle-transversely extending cylindrical inflator 11 (FIG. 3, FIG. 5 ), of which left and right ends 11 a (FIG. 5) are brought into abutment on both end plates 5 b of the lower portion 4 a of the retainer case 4 , but a cylindrical body 11 b (FIG. 3, FIG. 5) is spaced from a side wall 4 S (FIG. 2, FIG. 3, FIG. 4) of the lower portion 4 a , to be supported in a spatial position with a peripheral gap G (FIG. 3, FIG. 4, FIG. 5) left therebetween, by a total of eight resilient spacers 12 (FIG. 3, FIG. 5 ). The spacers 12 are arranged as left and right sets each respectively having a total of four equi-angularly spaced spacers 12 fixed to insides of upper fromt and rear parts 4 f and 4 g (FIG. 3) and lower front and rear parts 4 h and 4 I (FIG. 3, FIG. 5) corresponding in angular position to the above-noted lower front and rear parts 4 d and 4 e of the side wall 4 S of the lover portion 4 a of the retainer case 4 . The body 11 b of the inflator 11 is formed with a total of twenty gas discharge holes 13 (FIG. 3, FIG. 5) aligned into four axial arrays (FIG. 3) equi-angularly spaced about a center axis Ca (FIG. 3) thereof. Each axial array has five discharge holes 13 (FIG. 5) at five axial points P 1 to P 5 (FIG. 5) equi-dividing an axial length L (FIG. 5) of a side wall of inflator body 11 b, so that, along a respective one of five circumferences C 1 to C 5 (FIG. 5) passing the axial points P 1 to P 5 , a total of four gas discharge holes 13 are equi-angularly spaced. The inflator 11 installed is set in a position rotated at a specified angle so that a reference center plane Pz ((FIG. 3) of the inflator 11 , which passes the center axis Ca and respective top and bottom holes 13 , coincides with a reference center plane Pz 0 (FIG. 3) of the inclined retainer case 4 , and a plane Px (FIG. 3) perpendicular to the reference center plane Pz and passing the center axis Ca of the inflator 11 passes respective front and rear holes 13 . The above-noted upper and lower front and rear parts 4 d and 4 e, 4 f and 4 g, and 4 h and 4 i of the side walls 4 S, where the brackets 7 and/or the spacers 12 are mounted, are located on or near bisecting planes of four quadrants between the planes Pz and Px, so that the brackets 7 and the spacers 12 as well as their mounting structures are best positioned to be free from significant thermal effects of hot gases from the inflator 11 .

The side wall 4 S of the lower portion 4 a of the retainer case 4 is formed with a vehicle-transversely extending front bead 14 (FIG. 2, FIG. 3) in front of the front gas discharges holes 13 , serving as an outward bulged portion to increase the rigidity of the retainer case 4 , and concurrently as an outward recess to receive discharged gases from the holes 13 . Like bead may be formed in opposition to any rear or bottom gas discharge hole 13 of the inflator 11 .

The intermediate portion 4 b of the retainer case 4 has a rectangular diffuser member 15 (FIG. 3, FIG. 4, FIG. 5) fitted therein, with a peripheral part 8 b (FIG. 3, FIG. 4, FIG. 5) of a gas introducing inlet 8 a (FIG. 3, FIG. 4, FIG. 5) of the airbag 8 inserted therebetween. The diffuser member 15 is integrally formed with a rectangular main portion 15 a (FIG. 3, FIG. 4, FIG. 5 ), an inward extended portion 15 b (FIG. 3, FIG. 4, FIG. 5 ), and an outward flanged portion 15 c (FIG. 3, FIG. 4 ). The main portion 15 a of the diffuser member 15 is upwardly raised at the inside to be recessed at the outside, so as to cooperate with raised spread ends 4 j (FIG. 4) of the intermediate part 4 b of the retainer case 4 , which are supported from below by vehicular front and rear cross members 24 (FIG. 3, FIG. 4) fixed in position, for retaining therebetween the peripheral part 8 b of the gas introducing inlet 8 a of the airbag 8 . The main portion 15 a is constituted with a vehicle-transversely extending front part 15 d (FIG. 3, FIG. 4 ), vehicle-longitudinally extending left and right side parts 15 a ′ (FIG. 5 ), and a vehicle-transversely extending rear part 15 e (FIG. 3 ). The rear part 15 e of the main portion 15 a has an upwardly bent front edge 15 g (FIG. 3 ). The inward extended portion 15 b of the diffuser member 15 is once bent upward at an inner or rear end 15 f (FIG. 3, FIG. 4) of the front part 15 d of the main portion 15 a , to have a stepped part 15 h (FIG. 4 ), and then inwardly or rearwardly extended therefrom, and is furcated to provide beams 15 i (FIG. 5 ), which may be joined to the front edge 15 g of the rear part 15 e of the main portion 15 a , and grids 15 j (FIG. 5) for receiving the folded airbag 8 . The inward extended portion 15 b , is configured to cooperate with the left and right sides parts 15 a ′ and the rear part 15 e of the main portion 15 a to define a gas inlet 16 (FIG. 3) in direct communication with the gas introducing inlet 8 a of the airbag 8 . The gas inlet 16 is angularly offset clockwise (FIG. 3) relative to the top gas discharge holes 13 of the inflator 11 , to thereby effect adequate diffusion of gas in the gas diffusion chamber 5 , or more specifically, along the gap G between the inflator 11 and wall of the lower portion 4 a of the retainer case 4 . The outward flanged portion 15 c (FIG. 3, FIG. 4) is spread as an outward extension of the main portion 15 a for fixation by unshown fastening elements, such as bolts and nuts, to the upper portion 4 c of the retainer case 4 , and bent upward at the end to facilitate application of the gas introducing inlet 8 a of the airbag, 8 . The raised front part 15 d of the main portion 15 a may be fastened tight, together with the raised spread ends 4 j , to the cross members 24 or the like.

The stepped part 15 h of the inward extended portion 15 b cooperates with a straight rear part 15 k (FIG. 4) including the rear end 15 f of the front part 15 d of the main portion 15 a of the diffuser member 15 , to constitute a vehicle-transversely extending inward projection 17 , or more specifically, an acute-angled inward projection outlined in section like two flat sides of a triangular prism. Likewise, the periphery 5 d of the upper arcuate region 5 a (FIG. 3) of the gas diffusion chamber 5 cooperates with an inner end 4 k (FIG. 4) of the intermediate portion 4 b of the retainer case 4 to constitute an acute-angled inward projection 18 (FIG. 3, FIG. 4) into an upper front region Gf (FIG. 3, FIG. 4) of the gap G between the inflator 11 and the lower portion 4 a of the retainer case 4 , where gases discharged from the inflator 11 are yet being diffused, and a substantially right-angled inward projection 19 into an upper rear region Gr (FIG. 3) of the gap G, where discharged gases are diffused enough to be introduced into the clockwise offset gas inlet 8 a. The inward projections 17 and 18 cooperate with each other to define therebetween a straight gap or space S 1 (FIG. 3, FIG. 4) as a relatively thin and deep gaseous fluid path stopped by a corresponding part of an edge 8 c (FIG. 4) of the peripheral part 8 b of the gas introducing inlet 8 a of the airbag 8 . The space S 1 is by far higher in fluid resistance than the upper front region Gf of the gap G, where high-pressure, high-temperature gases thus have reduced tendencies to flow along streamline Ft into the space S 1 , so that gases are diffused along streamlines F 2 and F 3 . Likewise, the inward projection 19 cooperates with the front edge 15 g of the rear part 15 e of the main portion 15 a of the diffuser member 15 to define therebetween a straight gap or space S 2 (FIG. 3) as a relatively thin and shallow gaseous fluid path stopped by a corresponding part of the edge 8 c of the peripheral part 8 b of the gas introducing inlet 8 a of the airbag 8 . The space S 2 is higher in fluid resistance than the upper rear region Gr of the gap G, where diffused gases have reduced tendencies to flow into the space S 2 . The corresponding parts of the edge 8 c of the airbag 8 are spaced along the spaces S 1 and S 2 at effectively increased distances from the gap G.

Upon detection of a greater sudden deceleration of or impact on the vehicle than specified, an unshown sensor is operated to send a deployment signal to the inflator 11 , whereby a chemical in the inflator 11 is ignited, and high-pressure, high-temperature gases are discharged from the gas discharge holes 13 into the gas diffusion chamber 5 . Discharged gases fill the gas diffusion chamber 5 in a diffused state, so that diffused gases are sent via the gas inlet 16 and the gas introducing part 8 a into the airbag 8 , which is thereby inflated. In the course of inflation, the airbag 8 guided by the guide wall portion 3 b tears the lid portion 3 a of the lid member 3 , deploying inside the occupant room, thereby receiving an occupant seated on an navigator sheet, to protect the occupant from falling forward.

According to this embodiment, although a front end of an airbag 8 confronts a gas diffusion chamber 5 through a gap or space S 1 , because a path length or distance increasing structure configured with inward projections 17 and 18 is provided on or near both opposite sides of the space S 1 , the length of a path between from inside of the gas diffusion chamber 5 to the end of the airbag 8 is effectively elongated along the space Si, or more specifically (as is understood herein) along one of or along a centerline between opposing contours or surfaces of the projections 17 and 18 , so that gases entering the space S 1 have a little lowered temperatures when brought into contact with the end of the airbag 8 , which thus hardly receives undue thermal effects from hot gases. Moreover, around an entrance of the space S 1 , gases tend to flow along inclined surfaces of the inward projections 17 and 18 , like streams of convection, and have tendencies reduced by the projections 17 and 18 to flow into the space S 1 , where thermal effects are reduced accordingly. At an opposite (rear) side of the airbag 8 , where another space S 2 is adjacent to a relatively large gas inlet 16 , gases wholly flow toward the gas inlet 16 , with yet reduced tendencies to enter the space S 2 , which is thus inherently subject to little thermal effects. It should however be noted that the front edge 15 g of the rear part 15 e of the main portion 15 a of the diffuser member 15 may also be formed with an inward projection analogous to the projection 17 at the front side. It should also be noted that the projections 17 and 18 constitute a gas invasion restricting structure for restricting an invasion of gas from the diffusion chamber 5 along the space S 1 , i.e. a gas invasion into between the intermediate portion 4 b of the retainer case 4 and the diffusion member 15 .

Further, because a portion 4 a of a retainer case 4 defining the diffusion chamber 5 has a bead 14 formed therein in correspondence to front gas discharge holes 13 of the inflator 11 , the bead 14 has a greater distance than other inside surfaces of the portion 4 a relative to the gas discharge holes 13 , so that the retainer case 4 is subject to smaller thermal effects than ever. This reduction of thermal effects at a gas contacting surface (bead 14 ) of the retainer case allows fixtures, such as brackets 7 , to be attached to the retainer case 4 at closer positions to the gas contacting surface than ever.

Second Embodiment

FIG. 6 shows a second embodiment of the invention. In this embodiment, an intermediate portion 30 of a retainer case 4 has: a non-linear base part 31 formed with a base end 31 a frontwardly upwardly bent from a peripheral part 5 d of a lower portion 4 a of the retainer case 4 , and a deformed part 31 b deformed in an inverted-U form; a mounting part 32 extending frontwardly upward from a front end of the deformed part 31 b; and a distal end part 33 extending upward from a front end of the mounting part 32 .

A diffuser member 40 is integrally formed with a main portion 41 rectangular in plan, and an inward extended portion 42 provided as a rearward extension of a front part of the main portion 41 . The main portion 41 is formed with: a non-linear deformed part 41 a deformed in an inverted-U form similar to and loose-fitted on the non-linear base part 31 of the above-noted intermediate portion 30 , with a non-linear (i.e. inverted-U) connected space S 3 left as a gap therebetween; and a retaining part 41 b extending frontwardly upward from a front end of the deformed part 41 a. The retaining part 41 b is fastened tight to a vehicular cross member 24 , by bolts 50 and nuts 51 , together with the mounting part 32 of the intermediate portion 30 , with a peripheral part 8 b of a gas introducing inlet 8 a of an airbag 8 inserted therebetween. The inward extended portion 42 is once bent rearwardly upward at a rear end 41 c of the non-linear deformed part 41 a, and extended rearward like the first embodiment.

The non-linear space S 3 is defined as a relatively tin and deep U-shaped gaseous fluid path stopped by a corresponding part o edge 8 c of the peripheral part 8 B of the gas introducing inlet 8 a of the airbag 8 . The space S 3 is much higher in fluid resistance than an upper front region Gf of a gap G, where high-pressure, high-temperature gases having reduced tendencies to slow along streamline F 4 into the space S 3 .

According to this embodiment, because a front end of an airbag 8 indirectly confronts a gas diffusion chamber 5 through an inverted-U shape space S 3 , which is defined by a path length or distance increasing structure configured with deformed parts 31 and 41 a provided on both opposite sides of the space S 3 , the length of a path between from inside of the gas diffusion chamber 5 to the end of the airbag 8 is effectively elongated along the space S 3 , so that gases entering the space S 3 have lowered temperatures when brought into contact with the end of the airbag 8 , which thus hardly receives undue thermal effects from hot gases.

Third Embodiment

FIG. 7 shows a third embodiment of the invention. In this embodiment, an intermediate portion 130 of a retainer case 4 has a non-linear base part 131 formed with: a base end 131 a frontwardly upwardly bent from a peripheral part 5 d of a lower portion 4 a of the retainer case 4 ; a deformed part 131 b deformed in an inverted-V form; and a connection part 131 c for connection of the deformed part 131 b to a mounting part 32 of the intermediate portion 131 . A diffuser member 140 is integrally formed with a main portion 141 rectangular in plan, and an inward extended portion 142 provided as a rearward extension of a front part of the main portion 141 . The main portion 141 is formed with a non-linear deformed part 141 a and a retaining part 41 b. The non-linear deformed part 141 a is deformed in an inverted-V form similar to and loose-fitted on the non-linear base part 131 of the above-noted intermediate portion 130 , with the latter 131 one-sided, so that a rear side of the latter 131 is brought into abutment on a rear side of the former 141 a, and a non-linear (i.e. half-V) connected space S 4 is left as a gap between a front side of the former 141 a and a front side of the latter 131 . The inward extended portion 142 is bent at a rear end 141 c of the non-linear deformed part 141 a, and extended rearward like the first embodiment.

The non-linear space S 4 is defined as a relatively thin half-V-shaped gaseous fluid path stopped at the front end by a corresponding part of an edge 8 c of a peripheral part 8 b of a gas introducing inlet 8 a of an airbag 8 , and at the rear end by the rear side of the non-linear base part 131 abutting on the rear side of the non-linear deformed part 141 a. The space S 4 is extremely high in fluid resistance relative to an upper front region Gf of a gap G, where high-pressure, high-temperature gases have tendencies to flow along turning streamline F 5 .

According to this embodiment, because a front end of an airbag 8 is substantially isolated from a gas diffusion chamber 5 by a path length or distance increasing structure configured with deformed parts 131 and 141 a provided on both opposite sides of a space S 4 , gases in the diffusion chamber 5 is substantially kept from contacting the front end of the air bag 8 , which is thus kept free from undue thermal effects of hot gases.

The contents of Japanese Patent Application No. 2000-30630 are incorporated herein by reference.

While preferred embodiments of the present invention have been described using specific terms, such description is for illustrative purposes, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.