Air bag and a method of folding the air bag

1. An inflatable vehicle occupant protection device for location on a steering wheel for helping to protect an occupant of a vehicle, said inflatable vehicle occupant protection device comprising:

a lower portion and an upper portion,

said upper portion being roll folded and said lower portion being folded into a star pattern,

said roll folded portion having an outside surface formed by a front surface of said inflatable vehicle occupant protection device that is intended to face the occupant when said inflatable vehicle occupant protection device is inflated so that, during inflation of said inflatable vehicle occupant protection device, said roll folded portion unrolls in a direction such that at least a portion of said inflating inflatable vehicle occupant protection device inflates forward of the steering wheel if the inflatable vehicle occupant protection device, while inflating, encounters an obstruction located too far forward relative to the steering wheel.

2. The inflatable vehicle occupant protection device according to claim 1 further comprising a rear surface and wherein said star folded pattern comprises a plurality of folds in said lower portion extending perpendicularly to said front and rear surfaces around a partial perimeter of said inflatable vehicle occupant protection device.

3. The inflatable vehicle occupant protection device according to claim 1 wherein said inflatable vehicle occupant protection device is oriented on said steering wheel so that said upper portion is adjacent an upper rim of said steering wheel and said lower portion is adjacent the remainder of said steering wheel rim.

4. The inflatable vehicle occupant protection device according to claim 1 wherein, if said inflating inflatable vehicle occupant protection device does not encounter an obstruction while inflating, said inflatable vehicle occupant protection device inflates behind the steering wheel in the vehicle.

5. A method of folding an inflatable vehicle occupant protection device for location on a steering wheel for helping to protect an occupant of a vehicle, said inflatable vehicle occupant protection device when inflated comprising a lower portion and an upper portion, said method comprising the steps of:

folding at least said lower portion of said inflatable vehicle occupant protection device in a star pattern, and

rolling said upper portion of said inflatable vehicle occupant protection device to form a roll having an outside surface formed by a front surface of said inflatable vehicle occupant protection device that is intended to face the occupant when said inflatable vehicle occupant protection device is inflated so that, during inflation of said inflatable vehicle occupant protection device, said roll folded portion unrolls in a direction such that at least a portion of said inflatable vehicle occupant protection device inflates forward of the steering wheel if the inflatable vehicle occupant protection device, while inflating, encounters an obstruction located too far forward relative to the steering wheel.

6. The method according to claim 5 wherein said inflatable vehicle occupant protection device is circular and further comprising, preceding the step of folding at least said lower portion in a star pattern, the step of placing said inflatable vehicle occupant protection device between two spaced apart plates, and at least partially inflating said inflatable vehicle occupant protection device between said two plates to engage said two plates by directing air from a fan into said inflatable vehicle occupant protection device.

7. The method according to claim 6 further comprising, preceding the step of placing said inflatable vehicle occupant protection device between two spaced apart plates, the step of clamping only said upper portion so that said upper portion is not folded in said star pattern and releasing said clamping of said upper portion of said inflatable vehicle occupant protection device prior to the step of rolling said upper portion.

8. The method according to claim 7 wherein the step of folding at least said lower portion in a star pattern includes the step of moving a first plurality of folding paddles, arranged around at least a portion of the perimeter of said inflatable vehicle occupant protection device, into the inflatable vehicle occupant protection device to produce a first set of folds extending perpendicularly to and between said two plates.

9. The method according to claim 8 wherein the step of folding at least said lower portion in a star pattern includes the step of moving a second plurality of folding paddles, arranged around at least a portion of the perimeter of said inflatable vehicle occupant protection device and between the first plurality of folding paddles, into the inflatable vehicle occupant protection device to produce a second set of folds extending perpendicularly to and between said two plates.

10. The method according to claim 9 wherein the step of folding at least said lower portion in a star pattern includes the step of leaving said first plurality of folding paddles in the first set of folds while moving the second plurality of folding paddles into said inflatable vehicle occupant protection device.

11. The method according to claim 7 further comprising, preceding the step of rolling said inflatable vehicle occupant protection device, the step of removing at least one of said two plates.

12. The method according to claim 5 wherein the step of folding at least the lower portion of said inflatable vehicle occupant protection device in a star pattern includes the step of folding both said upper and lower portions of said inflatable vehicle occupant protection device in a star pattern.

13. The method according to claim 12 further comprising, after the step of folding both the upper and lower portions of said inflatable vehicle occupant protection device in a star pattern, the step of unfolding only the upper portion and thereafter rolling the upper portion.