Airbag unit for a motor vehicle safety device and a related method of packaging an airbag

1. An airbag unit for a motor vehicle safety device, the airbag unit comprising:

an inflatable airbag formed of a flexible material, the inflatable airbag in an uninflated condition selected from a group consisting of a rolled and a folded condition; and

a cover holding the inflatable airbag in the uninflated condition under compression,

wherein the cover is formed of a moulded pulp material, compresses the inflatable airbag in the uninflated condition and cooperates with the inflatable airbag to define a compressed package having a predetermined stable shape in the uninflated condition, and

wherein the cover completely extends around at least part of the inflatable airbag in the uninflated condition and independently maintains the predetermined stable shape of the compressed package.

2. The airbag unit according to claim 1 , wherein the moulded pulp material is derived from at least one renewable source.

3. The airbag unit according to claim 1 , wherein the moulded pulp material comprises cellulose fibres.

4. The airbag unit according to claim 1 , wherein the moulded pulp material comprises recycled paper.

5. The airbag unit according to claim 1 , wherein the moulded pulp material comprises natural fibres.

6. The airbag unit according to claim 1 , wherein the cover contains no polymeric material.

7. The airbag unit according to claim 1 , wherein the cover has a water-resistant or water-proof coating.

8. The airbag unit according to claim 1 , wherein the cover is substantially devoid of moisture.

9. The airbag unit according to claim 1 , wherein the cover substantially completely encapsulates the inflatable airbag.

10. The airbag unit according to claim 9 , wherein the moulded pulp material of the cover completely encapsulates the inflatable airbag.

11. The airbag unit according to claim 1 , wherein the moulded pulp material of the cover completely extends around at least part of the inflatable airbag in the uninflated condition.

12. The airbag unit according to claim 1 , wherein the moulded pulp material of the cover completely extends peripherally around at least part of the inflatable airbag in the uninflated condition.

13. A method of packaging an airbag for a motor vehicle safety device, the method comprising:

providing an inflatable airbag formed of flexible sheet material;

rolling and/or folding the airbag; and

providing a cover of moulded pulp material around at least part of the rolled and/or folded airbag via simultaneous application of heat and pressure to form a compressed package having a stable shape defined by the moulded pulp material.

14. The method according to claim 13 , further including:

at least partially enclosing the rolled and/or folded airbag within an initially flexible cover formed of semi-pulp material containing moisture to form an intermediate package; and

then simultaneously heating and pressing the intermediate package to eliminate the moisture and impart the stable shape to a resulting compressed package.

15. The method according to claim 14 , further including placing the intermediate package in a mould cavity prior to the step of simultaneously heating and pressing the intermediate package, and wherein the step of simultaneously heating and pressing is performed on the intermediate package within the mould cavity.

16. The method according to claim 15 , further including applying a vacuum to the mould cavity during the step of simultaneously heating and pressing.

17. The method according to claim 13 , wherein the moulded pulp material is derived from at least one renewable source.

18. The method according to claim 13 , wherein the moulded pulp material comprises cellulose fibres.

19. The method according to claim 13 , wherein the moulded pulp material comprises recycled paper.

20. The method according to claim 13 , wherein the moulded pulp material comprises natural fibres.