Knee airbag module

1. A knee airbag module for protecting a vehicle occupant comprising:

a housing containing an inflatable airbag and an inflator for providing gas for inflating the airbag; and

wherein the inflatable airbag is configured to inflate and deploy out of the housing into a position forward of knees of the vehicle occupant;

where the inflatable airbag includes front and rear panels that are connected together to form an inflatable chamber;

wherein when the inflatable airbag deploys the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein the front panel includes an opening and wherein edges of the opening are connected together to form a substantially horizontal pleat so that a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel; and

wherein the inflatable airbag first deploys rearwardly and then upwardly to a position where the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant.

2. A knee airbag module for protecting a vehicle occupant comprising:

a housing containing an inflatable airbag and an inflator for providing gas for inflating the airbag; and

wherein the inflatable airbag is configured to inflate and deploy out of the housing into a position forward of knees of the vehicle occupant;

where the inflatable airbag includes front and rear panels that are connected together to form an inflatable chamber;

wherein when the inflatable airbag deploys the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the inflatable airbag to deploy upwardly;

wherein at least one of the front and rear panels includes a substantially horizontal pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel;

wherein the substantially horizontal pleat is in the front panel; and

wherein the front panel includes an opening and the substantially horizontal pleat is formed in the front panel by connecting edges of the opening.

3. A knee airbag module for protecting a vehicle occupant comprising:

a housing containing an inflatable airbag and an inflator for providing gas for inflating the airbag; and

wherein the inflatable airbag is configured to inflate and deploy out of the housing into a position forward of knees of the vehicle occupant;

where the inflatable airbag includes front and rear panels that are connected together to form an inflatable chamber;

wherein when the inflatable airbag deploys the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the inflatable airbag to deploy upwardly;

wherein at least one of the front and rear panels includes a substantially horizontal first pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel;

wherein the substantially horizontal first pleat is in the front panel, and

further comprising a second pleat in the rear panel, wherein the second pleat is configured to reduce the perimeter of the rear panel to substantially match the perimeter the front panel.

4. The airbag module of claim 3 , wherein the front panel includes a folded portion and the substantially horizontal first pleat is formed by tucking the folded portion into the inflatable chamber.

5. The airbag module of claim 4 , wherein the front panel includes a substantially horizontal seam positioned to maintain the folded portion in the inflatable chamber.

6. The airbag module of claim 3 , wherein the front panel includes a folded portion and the substantially horizontal first pleat is formed to extend away from the inflatable chamber.

7. A knee airbag module for protecting a vehicle occupant comprising:

a housing containing an inflatable airbag and an inflator for providing gas for inflating the airbag; and

wherein the inflatable airbag is configured to inflate and deploy out of the housing into a position forward of knees of the vehicle occupant;

where the inflatable airbag includes front and rear panels that are connected together to form an inflatable chamber;

wherein when the inflatable airbag deploys the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the inflatable airbag to deploy upwardly;

wherein at least one of the front and rear panels includes a substantially horizontal pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel; and

wherein prior to connecting the first and second panels together to form the airbag cushion the length of the perimeter of the rear panel is greater than the length of the perimeter for the front panel, and wherein the pleat is in the rear panel.

8. The airbag module of claim 7 , wherein the pleat is formed by a connected pair of edge portions of the rear panel to thereby reduce the perimeter of the rear panel to substantially match the perimeter of the front panel.

9. The airbag module of claim 8 , wherein the rear panel includes a second pleat formed on a horizontally opposite side of the perimeter of the rear panel.

10. A knee airbag cushion for use in an airbag module for restraining a vehicle occupant comprising:

a front panel, and

a rear panel connected to the front panel to form an inflatable chamber;

wherein the inflatable chamber is configured to inflate to deploy the airbag cushion out of the airbag module into a position forward of the lower legs of the vehicle occupant;

wherein when the airbag deploys to the position forward of the lower legs of the occupant the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the airbag to deploy upwardly;

wherein at least one of the front and rear panels of the airbag cushion includes a substantially horizontal pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel;

wherein the substantially horizontal pleat is in the front panel; and

wherein the front panel includes an opening and the pleat is formed in the front panel connecting the edges of the opening.

11. A knee airbag cushion for use in an airbag module for restraining a vehicle occupant comprising:

a front panel, and

a rear panel connected to the front panel to form an inflatable chamber;

wherein the inflatable chamber is configured to inflate to deploy the airbag cushion out of the airbag module into a position forward of the lower legs of the vehicle occupant;

wherein when the airbag deploys to the position forward of the lower legs of the occupant the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the airbag to deploy upwardly;

wherein at least one of the front and rear panels of the airbag cushion includes a substantially horizontal first pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel;

wherein the substantially horizontal first pleat is in the front panel; and

further comprising a second pleat located in the rear panel, wherein the second pleat is configured to reduce the perimeter of the rear panel to substantially match the perimeter the front panel.

12. The airbag cushion of claim 11 , wherein the front panel includes a folded portion and the substantially horizontal first pleat is formed by tucking the folded portion into the inflatable chamber.

13. The airbag cushion of claim 12 , wherein the front panel includes a substantially horizontal seam positioned to maintain the folded portion in the inflatable chamber.

14. The airbag module of claim 11 , wherein the front panel includes a folded portion and the substantially horizontal first pleat is formed to extend away from the inflatable chamber.

15. A knee airbag cushion for use in an airbag module for restraining a vehicle occupant comprising:

a front panel, and

a rear panel connected to the front panel to form an inflatable chamber;

wherein the inflatable chamber is configured to inflate to deploy the airbag cushion out of the airbag module into a position forward of the lower legs of the vehicle occupant;

wherein when the airbag deploys to the position forward of the lower legs of the occupant the front panel is adjacent to an instrument panel of the vehicle and the rear panel is adjacent to the vehicle occupant;

wherein a cross-sectional vertical length of the front panel is shorter than a cross-sectional vertical length of the rear panel thereby causing the airbag to deploy upwardly;

wherein at least one of the front and rear panels of the airbag cushion includes a substantially horizontal pleat thereby resulting in the cross-sectional vertical length of the front panel being shorter than the cross-sectional vertical length of the rear panel; and

wherein prior to connecting the first and second panels together to form the airbag cushion the length of the perimeter of the rear panel is greater than the length of the perimeter for the front panel, and wherein the pleat is located in the rear panel.

16. The airbag cushion of claim 15 , wherein the pleat is formed by a connected pair of edge portions of the rear panel to thereby reduce the perimeter of the rear panel to substantially match the perimeter of the front panel.

17. The airbag cushion of claim 16 , wherein the rear panel includes a second pleat formed on a horizontally opposite side of the perimeter of the rear panel.