Method to manufacture airbag mini packs

1. A method of forming a folded airbag cushion ( 10 , 10 A) comprises the steps of:

providing an airbag cushion made of fabric material ( 12 );

placing the cushion ( 10 , 10 A) in a vacuum bag ( 20 ) and evacuating the air to create a vacuum and shrinking the airbag cushion to a compacted size;

providing a shape forming contoured surface ( 102 a ) of a mandrel ( 102 ) against or within which the airbag cushion ( 10 , 10 A) is positioned on the mandrel and draped over the contoured surface ( 102 a ) of the mandrel to be drawn tightly over the contoured surface ( 102 a ) of the mandrel ( 102 ) to follow the contour during the step of creating a vacuum and presetting the cushion at a temperature up to 200° C. to set the cushion fabric material ( 12 ) to take the contour of the mandrel ( 102 );

placing the airbag cushion ( 10 , 10 A) in a high temperature environment between +50° C. to +140° C. for a predetermined time to thermally set the fabric material ( 12 ) to maintain the compacted airbag cushion shape; and

releasing the vacuum and removing the thermally set airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ), the cushion maintaining the predetermined shape being formed as a mini pack or compacted airbag cushion ( 10 , 10 A).

2. The method of claim 1 wherein the predetermined time to thermally set the material ( 12 ) is up to 2 hours.

3. The method of claim 1 further comprises the step of:

applying a compressive load or force on the evacuated airbag cushion ( 10 , 10 A) prior to the step of thermally setting the fabric material ( 12 ) and removing the compression force prior to removing the airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ).

4. The method of claim 1 further comprises the step of:

folding the airbag cushion ( 10 , 10 A) prior to placing it in the vacuum bag ( 20 ).

5. A method of forming a folded airbag cushion ( 10 , 10 A) comprises the steps of:

providing an airbag cushion made of fabric material ( 12 );

inserting a simulator of an inflator ( 40 ) in the cushion ( 10 , 10 A) to mimic the shape of an inflator ( 40 ), the simulator providing a contour surface for the airbag, the airbag cushion being folded with the simulator inside;

placing the folded cushion ( 10 , 10 A) with the simulator in a vacuum bag ( 20 ) and evacuating the air to create a vacuum and shrinking the airbag cushion to a compacted size;

providing a shape forming contoured surface ( 102 a ) of a mandrel ( 102 ) against or within which the airbag cushion ( 10 , 10 A) is positioned on the mandrel and draped over the contoured surface ( 102 a ) of the mandrel to be drawn tightly over the contoured surface ( 102 a ) of the mandrel ( 102 ) to follow the contour during the step of creating a vacuum and presetting the cushion at a temperature up to 200° C. to set the cushion fabric material ( 12 ) to take the contour of the mandrel ( 102 );

placing the airbag cushion ( 10 , 10 A) in a high temperature environment at 85° C. for 1.5 hours to thermally set the fabric material ( 12 ) to maintain the compacted airbag cushion shape;

releasing the vacuum and cooling the cushion and removing the thermally set airbag cushion ( 10 , 10 A) from the vacuum bag ( 20 ), after cooling removing the simulator and replacing the simulator with a live inflator, the cushion maintaining the predetermined shape being formed as a mini pack or compacted airbag cushion ( 10 , 10 A).

6. The method of claim 1 further comprises the step of:

assembling the airbag cushion ( 10 , 10 A) about a curtain airbag fixture, dire or mandrel prior to the step of evacuation.

7. The method of claim 1 further comprises the step of:

placing the formed airbag cushion ( 10 , 10 A) in an airbag module housing ( 30 ) to form a module assembly.

8. The method of claim 1 wherein the relaxed folded airbag cushion ( 10 , 10 A) retains a size reduction in thickness in the range of 20% to 40% smaller compared to the same cushion folded but not processed using the method of claim 1 .

9. A compacted airbag cushion ( 10 , 10 A) made by the method of claim 1 .

10. A compacted airbag cushion ( 10 , 10 A) of claim 9 further comprising a module housing for storing the mini pack airbag cushion ( 10 , 10 A).