WO2012105956A1

WO2012105956A1 - Vehicle seat assembly with air bag guide

Info

Publication number: WO2012105956A1
Application number: PCT/US2011/023300
Authority: WO
Inventors: Michael Tracht; Karsten Mueller
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2011-02-01
Filing date: 2011-02-01
Publication date: 2012-08-09
Anticipated expiration: 2013-08-01

Abstract

In at least certain embodiments, the vehicle seat assembly comprises a frame, a seat pad, a trim cover extending over the seat pad and including a release seam adjacent the seat pad, and an air bag assembly within the trim cover. In accordance with this embodiment, the air bag assembly includes an inflator and an air bag inflatable to project outwardly from the seat through the air bag release seam of the trim cover. Further in accordance with this embodiment, the vehicle seat assembly further includes an air bag guide including an inner panel and an outer panel that are associated with the air bag assembly and each have a forward end connected to one side of the release seam on one of the trim panels.

Description

VEHICLE SEAT ASSEMBLY WITH AIR BAG GUIDE

TECHNICAL FIELD

The present invention relates to a vehicle seat assembly, and in particular, a seat assembly including an air bag.

BACKGROUND

Vehicles can be equipped with side air bags, which may be in the form of an air bag disposed within a vehicle seat assembly. One limitation of air bags that are located within a seat assembly, is that the air bag needs to break through the seating material before it can fully deploy to protect a vehicle occupant. During deployment, such an air bag may encounter foam, or other seat pad materials, and must then break through a seat trim cover in order to escape from the seat assembly. Another limitation is that the air bag should break through the cover material at a predetermined location to optimize effectiveness. Prior vehicle seat assemblies equipped with side air bags and manufacturing methods are disclosed in U.S. Patent Nos. 5,816,610, 5,860,673, 5,938,232, 6,045,151, 6,237,934, 6,588,838, 7,134,685, 7,731,226, 7,543,847, 7,637,529 and 7,654,612, for example.

SUMMARY Under the invention, a vehicle seat assembly is provided. In at least one embodiment, the vehicle seat assembly comprises a frame, a seat pad adjacent the frame, a trim cover extending over at least a part of the seat pad and including a side trim panel and a front trim panel connected together to form a release seam adjacent the seat pad, and an air bag assembly mounted on the frame within the trim cover in a spaced relationship from the air bag release seam. In accordance with this embodiment, the air bag assembly includes an inflator and a folded air bag that is inflatable by the inflator to unfold and project outwardly from the seat through the air bag release seam of the trim cover. Further in accordance with this embodiment, the vehicle seat assembly includes an air bag guide including an inner panel and an outer panel made of flexible material associated with the air bag assembly and having forward ends connected to each other adjacent one side of the release seam on one of the trim panels.

In at least one embodiment, the forward ends of the inner and outer panels are connected to each other on the front trim panel of the trim cover, such that the forward end of the outer panel extends further than the forward end of the inner panel upon deployment In at least another embodiment, the forward ends of the inner and outer panels are connected to each other on the side trim panel of the trim cover, such that the forward end of the inner panel extends further than the forward end of the outer panel upon deployment.

In at least another embodiment, the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel is disposed adjacent the forward end of the inner panel such that the forward end of the inner panel is disposed between the forward ends of the one trim panel and the outer panel.

In at least another embodiment, the forward end of the outer panel is disposed adjacent a forward end of the one trim panel, and the forward end of the inner panel is disposed adjacent the forward end of the outer panel such that the forward end of the outer panel is disposed between the forward ends of the one trim panel and the inner panel.

In at least another embodiment, the outer panel has an intermediate portion disposed adjacent a forward end of the one trim panel with the forward end of the outer panel being adjacent an intermediate portion of the one trim panel, and an intermediate portion of the inner panel being adjacent the forward end of the outer panel, and the forward end of the inner panel being adjacent the intermediate portion of the outer panel.

In at least another embodiment, the outer panel has an intermediate portion disposed adjacent a forward end of the inner panel with the forward end of the outer panel being adjacent an intermediate portion of the inner panel, and an intermediate portion of the inner panel being adjacent the forward end of the one trim panel, and the forward end of the inner panel being adjacent the intermediate portion of the outer panel.

In at least another embodiment, the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and an intermediate portion of the inner panel is disposed adjacent an intermediate portion of the one trim panel, the forward end of the outer panel is disposed adjacent the intermediate portion of the inner panel, and an intermediate portion of the outer panel is disposed adjacent the forward end of the inner panel. In at least another embodiment, the forward end of the inner panel is disposed adjacent an intermediate portion of the outer panel, and an intermediate portion of the inner panel is disposed adjacent a forward end of the outer panel, the forward end of the outer panel is disposed adjacent the intermediate portion of the inner panel, and an intermediate portion of the outer panel is disposed adjacent an intermediate portion of the one trim panel.

In at least another embodiment, the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the one trim panel, and the forward end of the outer panel and an intermediate portion of the outer panel are connected to each other to form an outer panel loop portion directly adjacent the inner panel loop portion.

In at least another embodiment, the forward end of the outer panel and an intermediate portion of the outer panel are connected to each other to form an outer panel loop portion directly adjacent the one trim panel, and the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the outer panel loop portion.

In at least another embodiment, the forward end of the outer panel is disposed adjacent an intermediate portion of the one trim panel and the outer panel has an intermediate portion disposed adjacent a forward end of the one trim panel, and the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the outer panel.

In at least another embodiment, the forward end of the inner panel is disposed adjacent an intermediate portion of the one trim panel and the inner panel has an intermediate portion disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel and an intermediate portion of the outer panel are connected to each other to form an outer panel loop portion directly adjacent the inner panel. In at least another embodiment, the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel extends between the front trim panel and the side trim panel out of the release seam.

In at least another embodiment, the forward end of the outer panel is disposed adjacent a forward end of the one trim panel, and the forward end of the inner panel extends between the front trim panel and the side trim panel out of the release seam. In at least another embodiment, the forward end of the inner panel is disposed adjacent an intermediate portion of the one trim panel and an intermediate portion of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel extends between the front trim panel and the side trim panel out of the release seam.

In at least another embodiment, the forward end of the outer panel is disposed adjacent an intermediate portion of the one trim panel and an intermediate portion of the outer panel is disposed adjacent a forward end of the one trim panel, and the forward end of the inner panel extends between the front trim panel and the side trim panel out of the release seam.

In at least another embodiment, a French seam extends through the one trim panel and the inner and outer panels of the air bag guide.

In at least another embodiment, the air bag guide comprises a unitary sheet that wraps around the air bag assembly. In yet at least another embodiment, the vehicle seat assembly comprises a frame, a seat pad adjacent the frame, and a trim cover extending over the seat pad that includes a front trim panel and a side trim panel cooperating to form a release seam adjacent the seat pad, with the trim cover having an outer surface and an inner surface. In this embodiment, the seat assembly further comprises an air bag assembly within the trim cover in a spaced relationship from the release seam, with the air bag assembly including an inflator and a folded air bag that is inflatable by the inflator to unfold and project outwardly from the seat through the release seam of the trim cover. In this embodiment, the seat assembly also further comprises a unitary sheet air bag guide including an inner panel and an outer panel having forward ends, the unitary sheet having a rear portion wrapped around the air bag assembly, and the forward ends being connected to one side of the release seam.

In still yet at least another embodiment, a method of making a vehicle seat assembly is provided. In this embodiment, the method comprises providing a frame, mounting a seat pad on the frame, and disposing a trim cover over the seat pad, with the trim cover including a release seam adjacent the seat pad. In this embodiment, the method further comprises providing an air bag assembly adjacent the frame within the trim, with the air bag assembly including an air bag that is inflatable to project outwardly from the seat through the release seam of the trim cover, and providing an air bag guide including a first panel and a second panel of sheet material having forward ends, associating the air bag guide with the air bag assembly, and connecting the forward end of the air bag guide to one side of the release seam.

While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a fragmentary side view of a portion of a seat assembly in accordance with the present invention;

FIGURE 2 is a fragmentary sectional view of the seat assembly shown in Figure 1, taken through line 2-2;

FIGURE 3 is a view similar to Figure 2 showing the parts in a different position;

FIGURE 4 is a fragmentary sectional view of a detail of the seat assembly shown in Figure 2;

FIGURE 5 is similar to Figure 4 showing another embodiment;

FIGURE 6 is similar to Figure 5 showing another embodiment;

FIGURE 7 is similar to Figure 6 showing another embodiment; FIGURE 8 is similar to Figure 7 showing another embodiment;

FIGURE 9 is similar to Figure 8 showing another embodiment;

FIGURE 10 is similar to Figure 9 showing another embodiment; and

FIGURE 11 is similar to Figure 10 showing another embodiment.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various alternative forms. The figures are not necessarily of scale, some features may be exaggerated or minimized to show details of particular components. Therefore specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or a representative basis for teaching one skilled in the art to variously employ the present invention.

Moreover, except where otherwise expressly indicated, all numerical quantities in this description and in the claims indicating amounts of materials or conditions of reactions and/or use are to be understood as modified by the word "about" in describing the broader scope of this invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials as suitable preferred for a given purpose in connection with the invention implies that mixtures of any two or more members of the group or class may be equally suitable or preferred.

Figure 1 shows a portion of a seat assembly 10 in accordance with the present invention. The seat assembly 10 includes a seat back 12, and seat pad 16 covered by a trim cover 18. As is well known, the seat assembly 16 includes a seat bottom (not shown). The trim cover 18 may be made of any suitable material such as cloth, vinyl or leather, etc. As is shown in Figure 1, in at least some embodiments, a relatively rigid plastic molding 14 can optionally be provided in the rear area of the seat assembly 10 to provide support and/or for aesthetics.

In at least one embodiment, the seat pad 16 is made from a molded polymeric material, such as a polyurethane foam. The use of a polymeric foam material to construct the seat pad 16 can be cost effective and can provide the flexibility needed to easily change the shape of the seat pad for different types of seat assemblies. Of course, other types of polymeric materials may be molded to form the seat pad 16.

Disposed within the seat back 12 is an air bag assembly, such as a side air bag assembly 20. While the side air bag assembly 20 is shown on the seat back 12, which is a usage for which it has particular utility, it is also possible for the side air bag assembly to be utilized with a seat bottom even though the seat back usage is specifically disclosed. Also, as illustrated, the air bag assembly 20 is located at an outboard lateral side or extremity of the seat to provide protection against adjacent vehicle structure, but it is also possible to have the side air bag assembly located at the inboard lateral side to provide protection against an adjacent vehicle occupant and to also have side air bag assemblies at both outboard and inboard locations for protection in both lateral directions.

As shown in Figure 2, the air bag assembly 20 includes an air bag 22 and an inflator 24, which is configured to supply inflation fluid such as gas to the air bag 22, thereby facilitating deployment of the air bag 22. In at least one embodiment, the air bag assembly 20 also includes a housing 40 which at least partially surrounds the air bag 22 and the inflator 24.

Also shown in Figure 2 is a portion of a seat frame 26 which can be used for mounting the seat assembly 10 to a vehicle. The seat pad 16 is disposed proximate the frame 26 and air bag assembly 20 and may be directly attached to the frame 26 at various points. The trim cover 18 includes a first or front panel 21 and a second or side panel 23 that cooperate to form an air bag release seam 28 which in at least one embodiment is adjacent to a side 30 of the seat pad 16. In at least one embodiment, the release seam 28 is 40 to 70 cm in length, but can be any suitable length.

The air bag assembly 20 is located within the trim cover 18 and may be conventionally mounted, such as on the frame 26, adjacent the air bag release seam 28 but in a spaced relationship from the release seam. The schematically illustrated folded air bag 22, upon deployment, is inflated by inflation fluid from the inflator 24 to unfold and project outwardly from the seat 10 through the air bag release seam 28 of the trim cover 18 (Figure 3).

With continuing reference to Figure 2, an air bag guide of the seat back component is generally indicated by 32 and includes an inner panel 34 and an outer panel 36 that are each made of any suitable sheet material effective to protect the seat pad 16 during deployment of the air bag 22. For example, a woven or non- woven cloth material, which may include natural or synthetic materials such as nylon. One material that is found to be effective is a polyester material, of the type from which the air bag 22 may be manufactured. The sheet material may be flexible or elastic. Regardless of the type of material used to make the air bag guide 32, the use of the air bag guide 32 can be helpful in reducing friction on the air bag 22 as it deploys. Although a polymer such as nylon may be particularly beneficial, even a fleece material will help reduce the friction on the air bag 22. This is because the air bag guide 32 inhibits contact between the deploying air bag 22 and the seat pad 16 and helps to prevent small particles from separating from the seat pad and being introduced into the vehicle compartment.

The inner and outer panels 34, 36 of the air bag guide 32 respectively include rear ends 42, 44 that can be attached suitably to the housing 40 and/or frame 26, and or to each other to effectively associate the air bag guide 32 with the housing 40 of the air bag assembly 20. As best shown in Figure 2, in this illustrated embodiment, the rear ends 42, 44 are attached to each other behind the air bag assembly 20. Alternatively, the rear ends 42 and 44 could be relatively spaced from each other and attached to opposite sides of the housing 40 or other structure such as the frame 26. Moreover, the inner and outer panels 34 and 36 could be opposite ends of an unitary sheet that wraps around the housing 40.

As best shown in Figure 4, the inner and outer panels 34, 36 of the air bag guide 32 respectively include forward ends 52, 54 attached to the trim cover 18 adjacent the release seam 28. The forward ends 52, 54 of the inner and outer panels 34, 36 can be attached to the trim cover 18 by any suitable manner. For instance, the forward ends 52, 54 can be attached to the trim cover 18 adjacent the tear seam 28 via stitching, ultrasonic welding, adhesive, etc., among other suitable manners. Also, in one embodiment, the trim cover 18 could be secured to the forward ends 52, 54 of the air bag guide 32 via in situ molding of a polymeric seat pad 16.

As can be seen in the illustrated embodiments, both of the panels 34 and 36 are attached to the trim cover 18 on the same side of the release seam 28. While most embodiments are illustrated as being attached to the trim cover 18 on the front panel 21 side of the release seam 28, it should be understood the arrangements can be laterally reversed, i.e., the mirror image, such that the panels 34 and 36 could be on the side panel 23 of the release seam 28.

In at least the embodiment illustrated in Figure 4, the forward end 52 of the inner panel 34 is connected directly to forward end 60 of the front panel 21 of the trim cover 18 and the forward end 54 of the outer panel 36 is connected directly to the forward end 52 of the inner panel 34 adjacent the release seam 28. Thus, both the forward ends 52, 54 of the inner and outer panels 34 and 36 are connected to the trim cover 18 on one (the same) side of the release seam 28. In this embodiment, the inner panel 34 has an intermediate portion 64 that is adjacent an intermediate portion 66 of the front panel 21 of the trim cover 18 and the outer panel 36 has an intermediate portion 68 that is adjacent the intermediate portion 66 of the inner panel 34, such that the forward end 54 and the intermediate portion 68 of the outer panel 36 are disposed between the forward end 52 and the intermediate portion 64 of the inner panel 34. Stitching 7, 9 and 11 can be used to connect the panels 34 and 36 to the front panel 21 of the trim cover 18. The stitching 7, 9, and 11 can be applied in any suitable manner. In one embodiment, stitching 7 is support stitching that is optionally first applied to the front panel 21 and the inner and outer air bag guide panels 34 and 36 to secure panels 34 and 36 to the front panel 21 of the trim cover 18. Then stitching 9 is applied to secure the side panel 23 to the front panel 21 and the panels 34 and 36. Stitching 11 is then applied, such as in a French seam, to secure the outer, or intermediate, portion 66 of the front panel 21 to the inner portion, or forward end 66, of the front panel 21 and the panels 34 and 36. An optional French-type seam 11 can be provided on the side panel 23. Moreover, while the French seam is described and illustrated as securing intermediate portion 66 of front trim panel 21 to forward ends 60 of front trim panel, any suitable seam arrangement can be used. In at least one embodiment, since the panels 34 and 36 are secured to one side of the release seam, the stitching 7 and 11 is weaker than stitching 9. In this embodiment, stitching 7 and 11 is 10% - 50% weaker than stitching 9. Furthermore, since the panels 34 and 36 are applied to the same side, such as to the front panel, one stitching 7 or connection means is eliminated. This allows for cheaper and simpler manufacture.

In at least one embodiment, the air bag guide 32 is effective to prohibit all contact between the deploying air bag 22 and the seat pad 16. This can help to prevent energy loss from the air bag 22 by decreasing friction and protecting the seat pad 16 from damage. This, in turn, can also help to reduce the deployment time for the air bag 22 and/or the amount of inflation fluid required to deploy the air bag.

In at least one embodiment, the inner and outer panels 34 and 36 of the air bag guide 32 form a deployment channel 38 for the air bag 22. As shown in Figures 2-3, the deployment channel 38 is oriented to facilitate deployment of the air bag 22 through the seam 28 in the trim cover 18. The panels 34 and 36 aid in tearing the release seam 28 by directing the deployment force of the air bag 22 to the release seam 28. In certain embodiments, the trim cover 18 can be more stretchable than the panels 34, 36. Upon deployment of the air bag assembly 20, as shown schematically in Figure 3, the deploying air bag 22 causes relative movement of the flexible inner and outer panels 34 and 36 away from each other which then provide a guiding function of the unfolding air bag 22 as it moves between the panels toward the air bag release seam 28 and eventually tears open the release seam for outward projection of the air bag to provide the occupant protection. The relative movement of the panels 34 and 36 causes shearing which generates shear forces on stitching 7, 9 and 11. This results in a quicker tearing of the stitching or seams attachment means than that caused by a typical tensile force. This can reduce the force needed to tear the stitching or the connection means, as the case may be, which in turn reduces deployment time.

Furthermore, as the air bag 22 deploys through the deployment channel

38, the air bag guide 32 acts as a blocking member that forms a barrier on two sides

39, 41 of the air bag 22, thereby inhibiting contact between the air bag 22 and the seat pad 16. Thus, the seat pad 16 is moved away from the air bag 22 as it deploys through the deployment channel 38. As can be further seen in Figure 3, in some embodiments, the forward end of the outer panel 36 extends further out than forward end 52 of the inner panel 34. In this embodiment, forward end 54 can extent 2-5 cm further than forward end 52 relative to each other or to a relative fixed point, such as the inflator 24. Extending forward end 54 further provides for additional protection from seat pad fragmentation and other possible deployment debris. The arrangement of the panels 34 and 36 could be reversed if additional protection was preferred for the passenger side rather than the outboard side. In this case, the forward end 52 and 54 would be connected on the side trim panel 23 thus having forward end 52 extending further than forward end 54 upon deployment.

As shown in Figures 3-4, the attachment of the forward ends 52, 54 to the seam 28 helps to facilitate deployment of the air bag 22 through the seam 28. This is because the deployment channel 38 opens as the air bag 22 is deployed, and this causes the release seam 28 to rupture directing the deploying air bag 22 to exert an outward force on the trim cover 18 at the seam 28; this helps to open the seam 28 to provide an easy exit for the air bag 22. Also attachment of the panels 34, 36 to the release seam 28 helps to ensure that the air bag 22 will deploy in the predetermined desired manner through the seam 28. Because the panels 34, 36 are connected to each other with the same connection or stitching, as the case maybe, as the trim panels 21 and 23 are connected to each other, relatively consistent deployment of air bag in seat assemblies 10 employing the air bag guide 32 and the use of shear forces are used to rupture the stitchings, or connections as the case may be.

As best shown in Figure 4, the seam 28 can be sewn, or otherwise attached, adjacent end portions of the panels 34, 36 of the air bag guide 32 where the end portions of panels 21 and 23 of trim cover 18 are attached to each other via stitching 9 to form the release seam 28 of the trim cover 18. This helps to transfer the shearing force from the air bag guide 32, and facilitates separation of the seam 28. Moreover, while the air bag guide 32 has been described and illustrated as being a unitary sheet or two separate inner and outer sheets, it should be understood that the air bag guide could comprise a plurality of spaced apart strips, such as 0.5 to 10 cm wide strips.

Figure 5 illustrates another embodiment of an arrangement of panels 34a, 36a forming air bag guide 32a. The air bag guide 32a is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32a illustrated in Figure 5 provides an arrangement where the forward ends 52a and 54a are spaced from each other.

In the arrangement illustrated in Figure 5, the outer panel 36a is directly adjacent the tear seam 28 and the front panel 21, and the inner panel 34a is sandwiched between the outer panel 36a, such that forward end 52a of the inner panel 34a is disposed between an intermediate portion 68a of the outer panel 36a of the air bag guide 32a and the forward end 54a of the outer panel 36a.

In the embodiment illustrated in Figure 5, the forward end 54a of the outer panel 36a is connected directly to an intermediate portion 66 of the front panel 21 of the trim cover 18 and the intermediate portion 68a of the outer panel 36a is connected directly the forward end 60 of the front panel 21 of the trim cover 18, and the forward end 52a of the inner panel 34a is connected directly to the intermediate portion 68a of the outer panel 36a and an intermediate portion 64a of the inner panel 34a is connected directly to the forward end 54a of the outer panel 36a. In this embodiment, the outer panel 36a has an intermediate portion 68a that is adjacent the forward end 60 of the front panel 21 of the trim cover 18 and the inner panel 34a has an intermediate portion 64a that is adjacent the forward end 54a of the outer panel 36a, such that the forward end 52a and the intermediate portion 64a of the inner panel 34a is disposed between the forward end 54a and the intermediate portion 68a of the outer panel 36a.

Figure 6 illustrates another embodiment of an arrangement of panels 34b, 36b forming air bag guide 32b. The air bag guide 32b is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32b illustrated in Figure 6 provides an arrangement where forward ends 52b and 54b are spaced from each other.

In the arrangement illustrated in Figure 6, the inner panel 34b is directly adjacent the tear seam 28 and the front panel 21, and the outer panel 36b is sandwiched between the inner panel 34b, such that forward end 54b of the outer panel 36b is disposed between an intermediate portion 64b of the inner panel 34b of the air bag guide 32b and an intermediate portion 68b of the outer panel 36b.

In the embodiment illustrated in Figure 6, the forward end 52b of the inner panel 34b is connected directly to the forward end 60 of the front panel 21 of the trim cover 18 and the intermediate portion 64b of the inner panel 34b is connected directly the intermediate portion 66 of the front panel 21 of the trim cover 18, and the forward end 54b of the outer panel 36b is connected directly to the intermediate portion 64b of the inner panel 34b and the intermediate portion 68b of the outer panel 36b is connected directly to the forward end 52b of the inner panel 34b. In this embodiment, the forward end 52b of the inner panel 34b is adjacent the forward end 60 of the front panel 21 of the trim cover 18 and the intermediate portion 64b of the inner panel 34b is adjacent the intermediate portion 66 of the side panel 21 of the trim cover 18, such that the forward end 54b and the intermediate portion 68b of the outer panel 36b is disposed between the forward end 52b and the intermediate portion 64b of the inner panel 34b.

Figure 7 illustrates another embodiment of an arrangement of panels 34c, 36c forming air bag guide 32c. The air bag guide 32c is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32c illustrated in Figure 7 provides an arrangement where forward ends 52c and 54c are spaced from each other and extend in the same direction.

In the arrangement illustrated in Figure 7, the inner panel 34c is directly adjacent the tear seam 28 and the front panel 21, and the outer panel 36c is sandwiched between the inner panel 34c. In this embodiment, the forward end 54c of the outer panel 36c is disposed between an intermediate portion 68c of the outer panel 36c of the air bag guide 32c and a loop portion 70c of the outer panel 70c. In this embodiment, the forward end 52c of the inner panel 34c is disposed between an intermediate portion 66 of the front trim panel 21 of the trim cover 18 and an intermediate portion 64c of the inner panel 34c, such that a loop portion 72c of the inner panel 34c is disposed adjacent the forward end 60 of the front trim panel 21 of the trim cover 18. This arrangement inhibits fraying of the forward ends 52c and 54c. Thus, hot die cutting or laser cutting of the panels 34c and 36c would not be particularly necessary. Fraying could be inhibited by the folded back forward ends 52c and 54c. Another beneficial effect is to increase the length of the panels 34c and 36c by folding the ends 52c and 54c back. If the length of the panels was increased without being folded back these would be slack and less tension on the panels during the air bag deployment, thereby increasing deployment time. Also the seam holds the panel ends in place so no folds affect visual appearance by unaligned folds. By increasing the length of the panel end, the area of foam that is protected can also be extended.

In the embodiment illustrated in Figure 7, the forward end 52c of the inner panel 34c is connected directly to the intermediate portion 66 of the front panel 21 of the trim cover 18 and the loop portion 72c of the inner panel 34c is connected directly to the forward end 60 of the front panel 21 of the trim cover 18, and the forward end 54c and the intermediate portion 68c of the outer panel 36c is connected directly to the intermediate portion 64c of the inner panel 34c and the loop portion 70c of the outer panel 36c is connected directly to the loop portion 72c of the inner panel 34c.

Figure 8 illustrates another embodiment of an arrangement of panels 34d, 36d forming air bag guide 32d. The air bag guide 32d is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32d illustrated in Figure 8 provides an arrangement where forward ends 52d and 54d are spaced from each other and extend in the same direction. This arrangement provides a beneficial visual appearance as the loops 70c and 72c are pointed towards the trim 18 which causes a welt, or bulge, thereby providing a more rugged appearance. This welt is shown as the front panel 21 protrudes higher than the side panel 23 as shown in Figure 8.

In the arrangement illustrated in Figure 8, the outer panel 36d is directly adjacent the tear seam 28 and the front panel 21, and the inner panel 34c is sandwiched between the outer panel 36d. In this embodiment, the forward end 54d of the outer panel 36d is disposed between an intermediate portion 68d of the outer panel 36d of the air bag guide 32d and the forward end 60 of the front trim panel 21 of the trim cover 18. In this embodiment, the forward end 52d of the inner panel 34c is disposed between an intermediate portion 66 of the front trim panel 21 of the trim cover 18 and an intermediate portion 64d of the inner panel 34d, such that a loop portion 72d of the inner panel 34d is disposed between a loop portion 70d of the outer panel 36d and the intermediate portion 66 of the front trim panel 21 of the trim cover 18.

In the embodiment illustrated in Figure 8, the forward end 54d of the outer panel 36d is connected directly to the forward end 60 of the front panel 21 of the trim cover 18, and the loop portion 72d of the inner panel 34d is connected directly to the intermediate portion 66 of the front panel 21 of the trim cover 18. In this embodiment, the intermediate portion 68d of the outer panel 36d is connected directly between the intermediate portion 64d of the inner panel 34d and the forward end 54d of the outer panel 36d such that the loop portion 70d of the outer panel 36d is connected directly to forward end 60 of the front panel 21 of the trim cover 18 with the loop portions 70d and 72d being connected to each other.

Figure 9 illustrates another embodiment of an arrangement of panels 34e, 36e forming air bag guide 32e. The air bag guide 32e is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32e illustrated in Figure 9 provides an arrangement where forward ends 52d and 54d are spaced from each other and extend in the same direction. This arrangement provides the longer panel for one side when the additional length isn't needed on the other side (or vice versa when the outer panel is looped and the inner is short).

In the arrangement illustrated in Figure 9, the outer panel 36e is directly adjacent the tear seam 28 and the front panel 21 and the inner panel 34e is sandwiched between the outer panel 36e. In this embodiment, the forward end 54e of the outer panel 36e is disposed adjacent the intermediate portion 66 of the front trim panel 21 of the trim cover 18, and the intermediate portion 68e of the outer panel 36e is disposed adjacent the forward end 60 of the front trim panel 21 of the trim cover 18. In this embodiment, the forward end 52e of the inner panel 34e is disposed between the intermediate portion 68e of the outer panel 36e and an intermediate portion 64e of the inner panel 34e, such that a loop portion 72e of the inner panel 34e is disposed between the intermediate portion 68e and the forward end 54e of the outer panel 36e.

In the embodiment illustrated in Figure 9, the forward end 54e of the outer panel 36e is connected directly to the intermediate portion 66 of the front panel 21 of the trim cover 18, and the intermediate portion 68e of the outer panel 36e is connected directly to the forward end 60 of the front panel 21 of the trim cover 18. In this embodiment, the intermediate portion 64e and the forward end 54e of the inner panel 34e are connected directly to each other such that the loop portion 72e of the inner panel 34e is connected between the forward end 54e and the intermediate portion 68e of the outer panel 36e. Figure 10 illustrates another embodiment of an arrangement of panels 34f, 36f forming air bag guide 32f. The air bag guide 32f is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32f illustrated in Figure 10 provides an arrangement where forward end 52f of the inner panel 34f is disposed adjacent the forward end 60 of the front panel 21 of the trim cover 18 and the outer panel 36f has a 1 to 5 cm forward end tab 54f that extends through the release seam 28 which can act as an air bag label. It should be understood that the width of the tab 54f can be thinner than the width of the remainder of the outer panel 36f.

In the embodiment illustrated in Figure 10, the forward end 52f of the inner panel 34f is connected directly to the forward end 60 of the front panel 21 of the trim cover 18, and an intermediate portion 64f of the inner panel 34f is connected directly to the intermediate portion 66 of the front panel 21 of the trim cover 18, and the forward end 54f of the outer panel 36f extends through stitching 9.

Figure 11 illustrates another embodiment of an arrangement of panels 34g, 36g forming air bag guide 32g. The air bag guide 32g is similar in construction, manufacture, and operation to the air bag guide 32 shown in Figures 2-4. The air bag guide 32g illustrated in Figure 11 provides an arrangement where forward end 52g of the inner panel 34g is disposed adjacent the intermediate portion 66 of the front panel 21 of the trim cover 18, and the intermediate portion 64g of the inner panel 34g is disposed adjacent the forward end 60 of the front panel 21, and the outer panel 36g has a 1-5 cm forward end tab 54g that extends through the release seam 28 which can act as a label. This inner panel 34g can be made considerably longer than outer panel 36g to provide additional shielding if needed. Such an arrangement may not work as well in the embodiment depicted in Figure 10 as the air bag may snag with end 52f upon deployment, whereas in the embodiment depicted in Figure 11, the end 52g is further out of the way of the path of deploying air bag 22. While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

WHAT IS CLAIMED IS: 1. A vehicle seat assembly comprising:

a frame;

a seat pad adjacent the frame;

a trim cover extending over at least a part of the seat pad, the trim cover including a side trim panel and a front trim panel connected together to form a release seam adjacent the seat pad;

an air bag assembly mounted on the frame within the trim cover in a spaced relationship from the release seam, the air bag assembly including an inflator and a folded air bag that is inflatable by the inflator to unfold and project outwardly from the seat through the release seam of the trim cover; and

an air bag guide including an inner panel and an outer panel that are each made of flexible material, the inner and outer panels being associated with the air bag assembly, the inner and outer panels each having a forward end connected to each other adjacent one side of the release seam on one of the trim panels.

2. The vehicle seat assembly of claim 1 , wherein the forward ends of the inner and outer panels are connected to each other on the front trim panel of the trim cover, such that the forward end of the outer panel extends further than the forward end of the inner panel upon deployment.

3. The vehicle seat assembly of claim 1 , wherein the forward ends of the inner and outer panels are connected to each other on the side trim panel of the trim cover, such that the forward end of the inner panel extends further than the forward end of the outer panel upon deployment.

4. The vehicle seat assembly of claim 1 , wherein the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel is disposed adjacent the forward end of the inner panel such that the forward end of the inner panel is disposed between the forward ends of the one trim panel and the outer panel.

5. The vehicle seat assembly of claim 1 , wherein the outer panel has an intermediate portion disposed adjacent a forward end of the one trim panel with the forward end of the outer panel being adjacent an intermediate portion of the one trim panel, and an intermediate portion of the inner panel being adjacent the forward end of the outer panel, and the forward end of the inner panel being adjacent the intermediate portion of the outer panel.

6. The vehicle seat assembly of claim 1 , wherein the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and an intermediate portion of the inner panel is disposed adjacent an intermediate portion of the one trim panel, the forward end of the outer panel is disposed adjacent the intermediate portion of the inner panel, and an intermediate portion of the outer panel is disposed adjacent the forward end of the inner panel.

7. The vehicle seat assembly of claim 1 , wherein the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the one trim panel, and the forward end of the outer panel and an intermediate portion of the outer panel are connected to each other to form an outer panel loop portion directly adjacent the inner panel loop portion.

8. The vehicle seat assembly of claim 1 , wherein the forward end of the outer panel and an intermediate portion of the outer panel are connected to each other to form an outer panel loop portion directly adjacent the one trim panel, and the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the outer panel loop portion.

9. The vehicle seat assembly of claim 1, the forward end of the outer panel is disposed adjacent an intermediate portion of the one trim panel and the outer panel has an intermediate portion disposed adjacent a forward end of the one trim panel, and the forward end of the inner panel and an intermediate portion of the inner panel are connected to each other to form an inner panel loop portion directly adjacent the outer panel.

10. The vehicle seat assembly of claim 1 , wherein the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel extends between the front trim panel and the side trim panel out of the release seam.

11. The vehicle seat assembly of claim 1 , wherein the forward end of the inner panel is disposed adjacent an intermediate portion of the one trim panel and an intermediate portion of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel extends between the front trim panel and the side trim panel out of the release seam.

12. The vehicle seat assembly of claim 1 , wherein the air bag guide comprises a plurality of panels, each of the plurality of panels having opposed end portions connected to the one trim panel, a French seam extends through the one trim panel and the inner and outer panels of the air bag guide.

13. The vehicle seat assembly of claim 1 , wherein the air bag guide comprises a unitary sheet that wraps around the air bag assembly.

14. A vehicle seat assembly comprising:

a frame;

a seat pad adjacent the frame;

a trim cover extending over the seat pad and including at lest a side panel and a front panel cooperating to form a release seam adjacent the seat pad, the trim cover having an outer surface and an inner surface;

an air bag assembly within the trim cover in a spaced relationship from the release seam, the air bag assembly including an inflator and a folded air bag that is inflatable by the inflator to unfold and project outwardly from the seat through the release seam of the trim cover; and a unitary sheet air bag guide including an inner panel and an outer panel, the inner and outer panels each having a forward end, the unitary sheet having a rear portion wrapped around the air bag assembly, and the forward ends of the inner and outer panels being connected to one side of the release seam.

15. The vehicle seat assembly of claim 14, wherein the forward ends of the inner and outer panels are connected to each other on the front panel of the trim cover.

16. The vehicle seat assembly of claim 14,wherein the forward ends of the inner and outer panels are connected to each other on the side panel of the trim cover.

17. The vehicle seat assembly of claim 14, wherein the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel is disposed adjacent the forward end of the inner panel such that the forward end of the inner panel is disposed between the forward ends of the one trim panel and the outer panel.

18. A method of making a vehicle seat assembly, said method comprising:

providing a frame;

mounting a seat pad on the frame;

disposing a trim cover over the seat pad, the trim cover including a release seam adjacent the seat pad;

providing an air bag assembly adjacent the frame within the trim, the air bag assembly including an air bag that is inflatable to project outwardly from the seat through the release seam of the trim cover; and

providing an air bag guide including a first panel and a second panel of sheet material having forward ends, associating the air bag guide with the air bag assembly, and connecting the forward end of the air bag guide to one side of the release seam.

19. The method of claim 18, wherein the forward ends of the first and second panels are connected to each other on the first side of the release seam.

20. The method of claim 17, wherein the forward ends of the first and second panels are connected to each other on the second side of the release seam and wherein the forward end of the inner panel is disposed adjacent a forward end of the one trim panel, and the forward end of the outer panel is disposed adjacent the forward end of the inner panel such that the forward end of the inner panel is disposed between the forward ends of the one trim panel and the outer panel.