US-12617365-B1 - Integrated roof rail airbag and interior trim assembly for automotive vehicles

US12617365B1US 12617365 B1US12617365 B1US 12617365B1US-12617365-B1

Abstract

The present disclosure teaches an integrated roof rail airbag/trim assembly and methods for attaching the integrated roof rail airbag/trim assembly to a vehicle body before a roof structure or glass roof has been attached. The attachment method may be performed with an automated robot. The integrated roof rail airbag/trim assembly includes an airbag carrier structural frame and a roof rail airbag assembly, which includes a roof rail airbag and a roof rail airbag inflator. The roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame. The airbag carrier structural frame may include a corrugated airbag carrier structural channel that is rigidly attached to a corrugated roof trim channel. The integrated roof airbag/trim assembly may have at least one automated grab point that is configured to permit automated robotic attachment of the integrated roof airbag/trim assembly to a vehicle body.

Inventors

Matthew D. Thomas
David A. King
Kristina M. Hubarth
Tanja Kryzaniwskyj

Assignees

GM Global Technology Operations LLC

Dates

Publication Date: 20260505
Application Date: 20250314

Claims (20)

1 . An integrated roof airbag/trim assembly, comprising: an airbag carrier structural frame; and a roof rail airbag assembly, comprising a roof rail airbag and a roof rail airbag inflator; wherein the roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame; wherein the airbag carrier structural frame comprises: an airbag carrier structural channel; a roof trim structural channel that is rigidly attached to the airbag carrier structural channel; and at least two airbag carrier attachment studs that are attached to the airbag carrier structural channel; wherein the integrated roof airbag/trim assembly comprises at least two automation grab points located at one end and at an opposite end of the airbag carrier structural channel, which are configured to permit automated robotic attachment of the integrated roof airbag/trim assembly to a vehicle body; wherein the integrated roof airbag/trim assembly has a beam bending stiffness that is greater than or equal to about 20 N−m 2 before the integrated roof airbag/trim assembly has been attached to the vehicle body; and wherein the beam bending stiffness is measured by performing a standardized ASTM 3-point or 4-point bending test.
2 . The integrated roof airbag/trim assembly of claim 1 , further comprising: an A-pillar body attachment bracket configured for attaching the roof rail airbag assembly to an A-pillar of the vehicle body; and a C-pillar body attachment bracket configured for attaching the roof rail airbag assembly to a C-pillar of the vehicle body.
3 . The integrated roof airbag/trim assembly of claim 2 , wherein the A-pillar body attachment bracket is hinged at one or more front locations; wherein the C-pillar body attachment bracket is hinged at one or more rear locations; wherein a front portion of the integrated roof airbag/trim assembly is folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body; and/or wherein a rear portion of the integrated roof airbag/trim assembly is folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body.
4 . The integrated roof airbag/trim assembly of claim 2 , wherein the airbag carrier structural frame, the A-pillar body attachment bracket, and the C-pillar body attachment bracket are: (a) located above the roof rail airbag assembly; and (b) are configured to provide a shaped, structural reaction surface that guides deployment of an activated roof rail airbag in an inwardly-downward direction pointing between an occupant's sitting position and a vehicle-side daylight opening.
5 . The integrated roof airbag/trim assembly of claim 1 , wherein the airbag carrier structural frame is structurally configured to transfer roof rail airbag deployment forces directly to the vehicle body, thereby causing airbag deployment in an inwardly-downward direction when the roof rail airbag is activated.
6 . The integrated roof airbag/trim assembly of claim 1 , wherein the integrated roof airbag/trim assembly is disposed in-between an A-pillar and a C-pillar of the vehicle body.
7 . The integrated roof airbag/trim assembly of claim 1 , wherein the roof rail airbag assembly comprises one or more support structures that are configured to transfer deployment forces generated by an activated roof rail airbag to a vehicle's body structure, while maintaining integrity of the integrated roof airbag/trim assembly during deployment of the activated roof rail airbag.
8 . A method, comprising: attaching a roof rail airbag assembly to an airbag carrier structural frame, thereby making an integrated roof airbag/trim assembly; then attaching the integrated roof airbag/trim assembly to a vehicle body; and then installing a roof structure or a glass roof on the vehicle body after the integrated roof airbag/trim assembly has been attached to the vehicle body; wherein the roof rail airbag assembly comprises a roof rail airbag and a roof rail airbag inflator; wherein the airbag carrier structural frame comprises: an airbag carrier structural channel; and a roof trim structural channel that is rigidly attached to the airbag carrier structural channel; wherein attaching the integrated roof airbag/trim assembly to the vehicle body comprises using an automated robot to perform the attaching; wherein attaching the integrated roof airbag/trim assembly to the vehicle body further comprises using an automated robot to grab at least two automation grab points located at one end and at an opposite end of the airbag carrier structural frame, and then using the automated robot to attach the integrated roof airbag/trim assembly to the vehicle body by using a plurality of airbag carrier attachment studs located along the airbag carrier structural channel; wherein the integrated roof airbag/trim assembly has a beam bending stiffness that is greater than or equal to about 20 N−m 2 before the integrated roof airbag/trim assembly has been attached to the vehicle body; wherein the beam bending stiffness is measured by performing a standardized ASTM 3-point or 4-point bending test, and wherein the roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame before the roof rail airbag assembly is attached to the vehicle body.
9 . The method of claim 8 , further comprising: folding back a front portion of the integrated roof airbag/trim assembly at a hinged A-pillar body attachment bracket; and/or folding back a rear portion of the integrated roof airbag/trim assembly at a hinged C-pillar body attachment bracket; thereby shortening a portion of the integrated roof airbag/trim assembly before attaching the integrated roof airbag/trim assembly to the vehicle body; and thereby creating a dimensional clearance that allows one or more body-side attachment studs to be fitted to the vehicle body during vehicle body manufacture.
10 . The method of claim 8 , wherein the roof rail airbag assembly is located in-between an A-pillar and a C-pillar of the vehicle body module.
11 . The method of claim 8 , wherein the roof rail airbag assembly comprises one or more support structures that are configured to transfer deployment forces generated by an activated roof rail airbag to a vehicle's body structure, while maintaining integrity of the integrated roof airbag/trim assembly during deployment of the activated roof rail airbag.
12 . The method of claim 8 , further comprising rigidly attaching the airbag carrier structural channel to the roof trim structural channel by riveting, spot welding, or adhesive joining.
13 . A vehicle, comprising: a vehicle body; a set of road wheels connected to the vehicle body; and an integrated roof airbag/trim assembly attached to the vehicle body; wherein the integrated roof airbag/trim assembly comprises: an airbag carrier structural frame; and a roof rail airbag assembly, comprising a roof rail airbag and a roof rail airbag inflator; wherein the airbag carrier structural frame comprises: an airbag carrier structural channel; a roof trim structural channel that is rigidly attached to the airbag carrier structural channel; and at least two attachment study attached to the airbag carrier structural channel; wherein the roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame before the roof rail airbag assembly is attached to the vehicle body; and wherein the integrated roof airbag/trim assembly comprises at least two automation grab points located at one end and at an opposite end of the airbag carrier structural frame, that are configured to permit automated robotic attachment of the integrated roof airbag/trim assembly to the vehicle body.
14 . The vehicle of claim 13 , wherein the integrated roof airbag/trim assembly has a beam bending stiffness that is greater than or equal to about 20 N−m 2 before the integrated roof airbag/trim assembly has been attached to the vehicle body; and wherein the beam bending stiffness is measured by performing a standardized ASTM 3-point or 4-point bending test.
15 . The vehicle of claim 13 , further comprising: an A-pillar body attachment bracket configured for attaching the roof rail airbag assembly to an A-pillar of the vehicle body; and a C-pillar body attachment bracket configured for attaching the roof rail airbag assembly to a C-pillar of the vehicle body.
16 . The vehicle of claim 15 , wherein the A-pillar body attachment bracket is hinged at one or more front locations; wherein the C-pillar body attachment bracket is hinged at one or more rear locations; wherein a front portion of the integrated roof airbag/trim assembly is folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body; and/or wherein a rear portion of the integrated roof airbag/trim assembly is folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body.
17 . The vehicle of claim 15 , wherein the airbag carrier structural frame, the A-pillar body attachment bracket, and the C-pillar body attachment bracket are: (a) located above the roof rail airbag assembly; and (b) are configured to provide a shaped, structural reaction surface that guides deployment of an activated roof rail airbag in an inwardly-downward direction pointing between an occupant's sitting position and a vehicle-side daylight opening.
18 . The vehicle of claim 13 , wherein the airbag carrier structural frame is structurally configured to transfer roof rail airbag deployment forces directly to a vehicle body, thereby causing airbag deployment in an inwardly-downward direction when the roof rail airbag is activated.
19 . The vehicle of claim 13 , wherein the integrated roof airbag/trim assembly is disposed in-between an A-pillar and a C-pillar of a vehicle body.
20 . The vehicle of claim 13 , wherein the roof rail airbag assembly comprises one or more support structures that are configured to transfer deployment forces generated by an activated roof rail airbag to a vehicle's body structure, while maintaining integrity of the integrated roof airbag/trim assembly during deployment of the activated roof rail airbag.

Description

This disclosure relates to integrated roof rail airbag/trim assemblies for automated robotic manufacture of automotive vehicles. Roof rail airbags are generally installed manually during vehicle manufacture, because automated robots may have difficulty in handling and manipulating a flexible, unsupported roof rail airbag assembly. SUMMARY The present disclosure teaches an integrated roof rail airbag/trim assembly and methods for attaching the integrated roof rail airbag/trim assembly to a vehicle body before a roof structure or glass roof has been attached. The attachment method may be performed with an automated robot. The integrated roof rail airbag/trim assembly includes an airbag carrier structural frame and a roof rail airbag assembly, which includes a roof rail airbag and a roof rail airbag inflator. The roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame. The airbag carrier structural frame may include a corrugated airbag carrier structural channel that is rigidly attached to a corrugated roof trim channel. The integrated roof airbag/trim assembly may have at least one automated grab point that is configured to permit automated robotic attachment of the integrated roof airbag/trim assembly to a vehicle body. In a first embodiment, an integrated roof rail airbag/trim assembly has an airbag carrier structural frame and a roof rail airbag assembly including a roof rail airbag and a roof rail airbag inflator; The roof rail airbag assembly is attached to, and is physically integrated with, the airbag carrier structural frame. The airbag carrier structural frame is made of an airbag carrier structural channel that is rigidly attached to a roof trim channel. The airbag carrier structural frame may be attached to an A-pillar of a vehicle body with an A-pillar body attachment bracket, and also may be attached to a C-pillar of the vehicle body with a C-pillar body attachment bracket. In some embodiments, the integrated roof airbag/trim assembly may have at least one automated grab point that permits automated robotic attachment of the integrated roof airbag/trim assembly to a vehicle body. The integrated roof airbag/trim assembly may have a beam bending stiffness that is greater than or equal to about 20 N−m2 before the integrated roof airbag/trim assembly has been attached to the vehicle body. In some embodiments, the roof rail airbag assembly includes one or more support structures that transfer deployment forces generated by an activated roof rail airbag to the vehicle's body structure, while maintaining integrity of the integrated roof airbag/trim assembly during deployment of the activated roof rail airbag. The integrated roof airbag/trim assembly may be positioned in-between an A-pillar and a C-pillar of the vehicle body. In some embodiments, the A-pillar body attachment bracket is hinged at one or more places and a front portion of a length of the integrated roof airbag/trim assembly may be folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body. In some embodiments, the C-pillar body attachment bracket is hinged at one or more places and a rear portion of a length of the integrated roof airbag/trim assembly may be folded back and shortened before the integrated roof airbag/trim assembly is attached to the vehicle body. The A-pillar body attachment bracket and the C-pillar body attachment bracket may be located above the roof rail airbag assembly and they may be configured to provide a shaped, structural reaction surface that guides deployment of an activated roof rail airbag in an inwardly-downward direction pointing between an occupant's sitting position and a vehicle-side daylight opening. In some embodiments, the airbag carrier structural frame is structurally configured to transfer roof rail airbag deployment forces directly to the vehicle body, thereby causing airbag deployment in the inwardly-downward direction when the roof rail airbag is activated. The roof rail airbag may have a stress concentration feature that is oriented parallel to a centerline along a length of the roof rail airbag, which permits airbag deployment in an optimum direction when the roof rail airbag is deployed. In some embodiments, an airbag/trim assembly method includes: (1) attaching a roof rail airbag assembly to an airbag carrier structural frame, thereby forming an integrated roof airbag/trim assembly, and then (2) attaching the integrated roof airbag/trim assembly to the vehicle body. The roof rail airbag assembly includes a roof rail airbag and a roof rail airbag inflator. The airbag carrier structural frame is made of an airbag carrier structural channel that is rigidly attached to a roof trim channel. The airbag/trim assembly method may use an automated robot to attach the integrated roof airbag/trim assembly to the vehicle body using one or more automation grab points on the integrated roof airbag/trim as