Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of airbags and safety modules. More particularly, the present disclosure relates to an improved safety module for a vehicle, which allows unobstructed deployment of airbags in the event of a collision while preventing the uncontrolled separation and flying of cover panels associated with the safety module during airbag deployment.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Airbags are important safety components in modern vehicles, designed to rapidly inflate and cushion passengers in the event of a collision, thereby reducing the risk of injury. Conventional airbag deployment systems include a guiding element that directs the path of the inflating airbag to protect passengers optimally.
[0004] In many existing safety systems, the guiding element has an opening or passageway through which the airbag deploys during a collision. This passageway is often covered by panels that are connected to the guiding element through hinges. The panels are designed to open and allow the airbag to extend outward during deployment. However, a significant issue with these conventional systems is that the hinges connecting the panels to the guiding element can become compromised during the rapid and forceful inflation of the airbag.
[0005] The intense pressure exerted by the inflating airbag can lead to the hinges breaking, chipping off, or becoming detached from the guiding element. When this occurs, the panels may separate completely from the guiding element, causing them to fly uncontrollably within the vehicle cabin. This uncontrolled movement of the panels can pose a significant safety hazard to the vehicle's occupants, potentially causing injury or further exacerbating the dangers of the collision.
[0006] There is, therefore, a need to overcome the above drawbacks, limitations, and shortcomings associated with existing airbag systems or safety modules, by providing an improved solution that ensures the airbag deployment mechanism functions as intended, while also preventing the uncontrolled separation and flying of cover panels during airbag deployment.

OBJECTS OF THE PRESENT DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0008] It is an object of the present disclosure to provide an improved safety module for a vehicle, which allows unobstructed deployment of airbags in the event of a collision while preventing the uncontrolled separation and flying of cover associated with the safety module during airbag deployment.

SUMMARY
[0009] The present disclosure relates to the field of airbags and safety modules. More particularly, the present disclosure relates to an improved safety module for a vehicle, which allows unobstructed deployment of airbags in the event of collision while preventing the uncontrolled separation and flying of cover associated with the safety module during airbag deployment.
[0010] An aspect of the present disclosure pertains to a safety module for a vehicle. The safety module comprises a housing having an opening, the housing adapted to accommodate an airbag associated with the safety module during deployment of the airbag, and one or more cover adapted to cover the opening of the housing. The one or more cover is connected to the housing through one or more hinge, where the one or more hinge is formed by one or more curved portions and one or more flat portions arranged adjacent to each other along a hinge axis. Further, the one or more flat portions comprise one or more rib protruding from an upper surface of the one or more flat portions which is adapted to be welded to an inner surface of a carrier of the vehicle. This arrangement of the one or more ribs adapted to be welded to an inner surface of a carrier restricts separation of the cover from the housing upon deployment of the airbag.
[0011] In an aspect, the airbag may be configured to inflate and extend out of the housing through the opening upon deployment, while moving the one or more cover to an open position.
[0012] In an aspect, the one or more cover may comprise a pair of panels arranged in a same plane in its closed position. Each of the panels may be connected to the housing through the respective hinges further adapted to pivot from pressure exerted by the airbag during deployment to allow the panels to extend out of the opening while rotating about the hinge axis associated with the one or more hinge. In another aspect, the one or more cover may comprise a single panel arranged in a same plane as that of the housing in its closed position.
[0013] In an aspect, the pair of panels may be connected by one or more breakable member in the closed portion. The one or more breakable member may be adapted to break from the pressure exerted by the airbag. The airbag upon its deployment may allow the separated panels to pivot. The separated panels may pivot in opposite direction to each other.
[0014] In an aspect, the one or more rib may extend along at least on a portion of a perimeter or edge of the one or more flat portion of the one or more hinge.
[0015] In an aspect, the one or more rib extends along at least on a portion in-between a centre and a perimeter or edge of the one or more flat portion of the one or more hinge. Wherein along a length of the one or more flat portion, the one or more rib completely overlaps with the one or more flat portion. Further, along a width of the one or more flat portion, the one or more ribs overlap only about one-third portion of the one or more flat portion.
[0016] In an aspect, the one or more rib may comprise a first welding rib extending along a first end of the one or more flat portions, where the first end of the corresponding flat portion is connected to the one or more cover. The one or more welding rib may further comprise a second welding rib extending along a second end, opposite to the first end, of the one or more flat portions, where the second end of the corresponding flat portion is connected to the housing.
[0017] In an aspect, the one or more rib may be located and be extending centrally along a length of the one or more flat portion of the one or more cover.
[0018] In an aspect, the one or more cover may be further connected to the housing through one or more second breakable member that are adapted to break from pressure exerted by the airbag during deployment and correspondingly allow the panels to pivot to the open position of the cover.
[0019] In an aspect, the housing may include a guiding portion adapted to guide the deployment of the airbag.
[0020] In an aspect, the housing or the safety module may be configured to be installed at predefined positions in the carrier of the vehicle. In an aspect, the carrier may be a dashboard of the vehicle. In another aspect, the carrier may be associated with a group comprising a steering wheel, door panels, rear side of seats, lateral sides of the seats, and roof panels of the vehicle.

BRIEF DESCRIPTION OF DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0022] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0023] FIG. 1 illustrates an exemplary isometric view of a first embodiment of the safety module, in accordance with an embodiment of the present invention.
[0024] FIG. 2A illustrates an exemplary side cross-sectional view of the hinge area of the safety module having curved portions, in accordance with an embodiment of the present invention.
[0025] FIG. 2B illustrates an exemplary side cross-sectional view of the hinge area of the safety module having flat portions, in accordance with an embodiment of the present invention
[0026] FIG. 2C to 2G illustrate exemplary top views of the hinge area of the safety module having the ribs in different configurations, in accordance with an embodiment of the present invention.
[0027] FIG. 3A illustrates an exemplary side cross-sectional view of the safety module in a normal (undeployed) condition where the cover is in a closed condition, in accordance with an embodiment of the present invention.
[0028] FIG. 3B illustrates an exemplary side cross-sectional view of the safety module in a deployed condition where the cover is in an open condition, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] The present disclosure relates to the field of airbags and safety modules. More particularly, the present disclosure relates to an improved safety module for a vehicle, which allows unobstructed deployment of airbags in the event of a collision while preventing the uncontrolled separation and flying of cover panels associated with the safety module during airbag deployment.
[0031] According to an aspect, the present disclosure elaborates upon a safety module for a vehicle. The safety module comprises a housing having an opening, the housing adapted to accommodate an airbag associated with the safety module during deployment of the airbag, and one or more cover adapted to cover the opening of the housing. The one or more cover is connected to the housing through one or more hinge, where the one or more hinge is formed by one or more curved portions and one or more flat portions arranged adjacent to each other along a hinge axis Further, the one or more flat portions comprise one or more rib protruding from an upper surface of the one or more flat portions which is adapted to be welded to an inner surface of a carrier of the vehicle. This arrangement of the one or more ribs adapted to be welded to an inner surface of a carrier restricts separation of the cover from the housing upon deployment of the airbag.
[0032] In an embodiment, the airbag can be configured to inflate and extend out of the housing through the opening upon deployment, while moving the one or more cover to an open position.
[0033] In an embodiment, the one or more cover can include a pair of panels arranged in a same plane in its closed position. Each of the panels can be connected to the housing through the respective hinges can be further adapted to pivot from pressure exerted by the airbag during deployment to allow the panels to extend out of the opening while rotating about the hinge axis associated with the one or more hinge. In another aspect, the one or more cover may comprise a single panel arranged in a same plane as that of the housing in its closed position.
[0034] In an embodiment, the pair of panels can be connected by one or more breakable member in the closed position. The one or more breakable member can be adapted to break from the pressure exerted by the airbag. The airbag upon its deployment can allow the separated panels to pivot. The separated panels can pivot in opposite direction to each other.
[0035] In an aspect, the one or more rib extends along at least on a portion in-between a centre and a perimeter or edge of the one or more flat portion of the one or more hinge. Wherein along a length of the one or more flat portion, the one or more rib completely overlaps with the one or more flat portion. Further, along a width of the one or more flat portion, the one or more ribs overlap only about one-third portion of the one or more flat portion.
[0036] In an embodiment, the one or more rib can extend along at least on a portion of a perimeter or edge of the one or more flat portion of the one or more hinge.
[0037] In an embodiment, the one or more rib can include a first welding rib extending along a first end of the one or more flat portions, where the first end of the corresponding flat portion is connected to the one or more cover. The one or more welding rib can further include a second welding rib extending along a second end, opposite to the first end, of the one or more flat portions, where the second end of the corresponding flat portion is connected to the housing.
[0038] In an embodiment, the one or more rib can be located and extended centrally along a length of the one or more flat portion of the one or more cover.
[0039] In an embodiment, the one or more rib can be configured on an upper surface of the one or more flat portions.
[0040] In an embodiment, the one or more cover can be further connected to the housing through one or more second breakable member that are adapted to break from pressure exerted by the airbag during deployment and correspondingly allow the panels to pivot to the open position of the cover.
[0041] In an embodiment, the housing can include a guiding portion. The guiding portion can be adapted to guide the deployment of the airbag.
[0042] In an embodiment, the housing or the safety module can be configured to be installed at predefined positions in the carrier of the vehicle. In an aspect, the carrier may be a dashboard of the vehicle. In another aspect, the carrier can be associated with a group including a steering wheel, door panels, rear side of seats, lateral sides of the seats, and roof panels of the vehicle.
[0043] Referring to FIGs. 1 to 3B, in an embodiment, the proposed safety module 100 is disclosed. The safety module 100 can include a hollow housing 102 having an opening 102-1. The housing 102 can be adapted to accommodate an airbag 300 associated with an airbag system, out of the housing 102 via the opening 102-1, during deployment of the airbag 300. The safety module 100 can further include one or more cover 104 (collectively referred to as cover or door 104, herein) attached to the housing 102 to close the opening 102-1 and secure the airbag 300 within the housing 102 in an undeployed condition as shown in FIG. 3A.
[0044] In an embodiment, the cover 104 can be connected to the housing 102 (at the rim area R of the opening 102-1 as shown in FIGs. 3A and 3B) using one or more hinge 106-A to 106-N (collectively designated as the hinge 106, herein). Further, the one or more hinge 106 can include curved portion(s) 106-1 and flat portions 106-2 (collectively designated as flat portions 106-2, herein) arranged adjacent to each other along a hinge axis (as shown in FIG. 1). As illustrated in FIG. 2C to 2F, a first end of the curved portion 106-1 and the flat portions 106-2 can be connected to the cover 104 and a second end of the curved portion 106-1 and the flat portions 106-2 can be connected to the housing 102.
[0045] The flat portions can further include one or more rib 108 (collectively referred to as rib or rib 108, herein) configured on an upper surface of the flat portions 106-2 of the hinge 106. The one or more rib 108 are adapted to be welded on an inner portion of a carrier of the vehicle which may restrict flying or separation of the cover 104 from the housing 102 upon opening of the cover 104 when the airbag 300 is deployed. Accordingly, when the airbag 300 is inflated in the event of collision of the vehicle, the inflating airbag 300 move out of the housing 102 through the opening 102-1 may be guide by a guiding portion (not shown), while pivoting the cover 104 (panels 110-A, 110-B) outwards to an open position as shown in FIG. 3A. However, the rib 108 provides additional strength to the hinge 106 such that it can restrict flying or separation of the corresponding cover 104 (panels 110-A, 110-B) from the housing 102 upon movement of the cover 104 to the open position, without obstructing the deployment of the airbag 300 as shown in FIG. 3B.
[0046] In an embodiment, the cover 104 can include a pair of panels 110-A, 110-B that can be connected to each other by one or more first breakable members 112. In addition, the cover 104 or panels 110-A, 110-B of the cover 104 can be further connected to the housing 102 through one or more second breakable member 114 such that the panels 110-A, 110-B remain connected to the housing 102 through the hinges 106 and the second breakable member 114, while the panels 110-A, 110-B remain connected by the first breakable members 112.
[0047] The first breakable members 112 and the second breakable member 114 can be made of fracturable material that can keep the panels connected to each other and the housing 102 to keep the opening closed in normal condition while breaking under pressure exerted by the airbag 300 during deployment, thereby separating the panels 110-A, 110-B and correspondingly allowing the separated panels 110-A, 110-B to extend out of the opening while rotating about a hinge axis A-A’ associated with the hinge 106. In an exemplary embodiment, the first breakable members 112 and the second breakable member 114 can be made of thin-walled aluminum or plastic, and/or perforated metal, alloys, or plastic, but is not limited to the like, which can break under pressure on the panels 110-A, 110-B or cover 104.
[0048] In an embodiment, as illustrated in FIG. 2C, the rib 108 can extend along the perimeter or edges of the corresponding hinge 106 or flat portion 106-2. Further, in another embodiment, as shown in FIG. 2D, the rib 108 can extend along a length of the flat portion 106-2 or hinge 106, such that the rib 108 remains in between and parallel to opposite ends (first end and second end) of the corresponding flat portions 106-2. Furthermore, in yet another embodiment, as shown in FIG. 2E, a first welding rib 108-A can extend along the first end of the flat portions 106-2, and a second welding rib 108-B can extend along a second end, opposite to the first end, of the flat portions 106-2.
[0049] Further, in a preferred embodiment, as shown in FIG. 2F, the one or more rib 108 can extend along at least on a portion in-between a centre and a perimeter or edge of the one or more flat portion 106-2 of the one or more hinge 106. More particularly, along a length of the one or more flat portion 106-2, the one or more rib 108 can completely overlap with the one or more flat portion 106-2, wherein along a width of the one or more flat portion (106-2), the one or more 108 can overlap only about one-third portion of the one or more flat portion 106-2. Furthermore, in yet another embodiment, as shown in FIG. 2G, a pair of first welding rib 108-A can extend along opposite edges that extend between the first end and the second end of the flat portions 106-2 in a direction perpendicular to the hinge axis A-A’, and a second welding rib 108-B can extend along a length of the flat portion 106-2 or hinge 106, such that the rib 108 remains in between and parallel to opposite ends (first end and second end) of the corresponding flat portions 106-2. Accordingly, these additional ribs 108 on the flat portions 106-2 of the hinges 106 can restrict the creation of multiple hinge axes and direct all the load to the primary hinge axis A-A’, which allows clear rotation of the cover panels 110, without uncontrollable separation from the housing 102.
[0050] Referring to FIG. 3A, when the airbag 300 is deflated in normal conditions, the housing 102 can accommodate the airbag 300 therewithin and the cover 104 can secure the airbag 300. As there is no pressure or force from the airbag 300, the first breakable members 112 and the second breakable member 114 can remain unfractured to keep the panels 110-A, 110-B connected. In addition, the hinges 106 can keep the cover 104 or panels 110-A, 110-B connected to the housing 102 to keep the opening 102-1 covered.
[0051] Referring to FIG. 3B, when the airbag 300 is inflated in the event of collision of the vehicle, the housing 102 can guide the inflating airbag 300 to move out of the housing 102 through the opening 102-1, while extending or rotating the cover 104 outwards to an open position. The pressure or force from the inflating airbag 300 can cause the first breakable members 112 and the second breakable member 114 to fracture or break, thereby separating the panels 110-A, 110-B from each other to expose the opening of the housing 102. However, the rib 108 can keep the panels 110-A, 110-B connected to the housing 102 and restrict flying or separation of the corresponding cover 104 from the housing 102 upon movement of the cover 104 to the open position, without obstructing the deployment of the airbag 300.
[0052] Those skilled in the art would appreciate that while various embodiments and drawings of the present disclosure have been elaborated for the safety module 100 having a single cover 104 and a pair of panels 110-A, 110-B forming the respective cover 104 for the sake of simplicity and better explanation, however, the teachings of the present disclosure are equally applicable for the safety module 100 having any number of covers or panels without any limitations, and all such embodiments are well within the scope of the present disclosure.
[0053] In an embodiment, the housing 102 or the safety module 100 can be configured to be installed at predefined positions in the carrier of the vehicle such that only the door remains seamlessly visible from the interior of the vehicle. In an embodiment, the carrier for the airbag system or the safety module 100 can be at any or a combination of a steering wheel, a dashboard, door panels, rear side of seats, lateral sides of the seats, roof panels of the vehicle, but not limited to the like.
[0054] Thus, the present invention overcomes the drawbacks, limitations, and shortcomings associated with existing airbag systems or safety modules, by providing an improved safety module that ensures the airbag deployment mechanism functions as intended, while also preventing the uncontrolled separation and flying of cover during airbag deployment.
[0055] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0056] The proposed invention overcomes the shortcomings, drawbacks, and limitations associated with existing airbag systems and safety modules of vehicles.
[0057] The proposed invention restricts the chipping off or breakage of cover panels from the hinge area of the guiding element.
[0058] The proposed invention allows unobstructed deployment of airbags in the event of a collision while preventing the uncontrolled separation and flying of cover panels associated with the safety module during airbag deployment.
[0059] The proposed invention provides an improved safety module for a vehicle, which allows unobstructed deployment of airbags in the event of collision while preventing the uncontrolled separation and flying of cover panels associated with the safety module during airbag deployment.

, Claims:1. A safety module (100) for a vehicle, the safety module (100) comprising:
a housing (102) having an opening (102-1), the housing (102) adapted to accommodate an airbag (300) associated with the safety module (100) during deployment of the airbag (300); and
one or more cover (104) adapted to cover (104) the opening (102-1) of the housing (102), the one or more cover (104) is connected to the housing (102) through one or more hinge (106), wherein the one or more hinges (106) is formed by one or more curved portions (106-1) and one or more flat portions (106-2) arranged adjacent to each other along a hinge axis (A-A’), and
wherein the one or more flat portions (106-2) comprise one or more rib (108) protruding from an upper surface of the one or more flat portions (106-2) which is adapted to be welded to an inner surface of a carrier of the vehicle.
2. The safety module (100) as claimed in claim 1, wherein the airbag (300) is configured to inflate and extend out of the housing (102) through the opening (102-1) upon deployment while moving the one or more cover (104) to an open position.
3. The safety module (100) as claimed in claim 1, wherein the one or more cover (104) comprises a pair of panels (110-A, 110-B) arranged in a same plane in its closed position, wherein each of the panels (110-A, 110-B) is connected to the housing (102) through the respective hinges (106) further adapted to pivot from pressure exerted by the airbag (300) during deployment to allow the panels (110-A, 110-B) to extend out of the opening (102-1) while rotating about the hinge axis A-A’ associated with the one or more hinge (106).
4. The safety module (100) as claimed in claim 3, wherein the pair of panels (110-A, 110-B) are connected by one or more first breakable member (112) in the closed portion adapted to break from the pressure exerted by the airbag (300) upon its deployment to allow the separated panels (110-A, 110-B) to pivot is opposite direction to each other.
5. The safety module (100) as claimed in claim 1, wherein the one or more rib (108) extends along at least on a portion of a perimeter or edge of the one or more flat portion (106-2) of the one or more hinge (106).
6. The safety module (100) as claimed in claim 1, wherein the one or more rib (108) extends along at least on a portion in-between a centre and a perimeter or edge of the one or more flat portion (106-2) of the one or more hinge (106).
7. The safety module (100) as claimed in claim 6, wherein along a length of the one or more flat portion (106-2), the one or more rib (108) completely overlaps with the one or more flat portion (106-2), wherein along a width of the one or more flat portion (106-2), the one or more rib (108) overlaps only about one-third portion of the one or more flat portion (106-2).
8. The safety module (100) as claimed in claim 1, wherein the one or more rib (108) comprises:
a first welding rib (108-A) extending along a first end of the one or more flat portions (106-2), wherein the first end of the corresponding flat portion (106-2) is connected to the one or more cover (104); and/or
a second welding rib (108-B) extending along a second end, opposite to the first end, of the one or more flat portions (106-2), wherein the second end of the corresponding flat portion (106-2) is connected to the housing (102).
9. The safety module (100) as claimed in claim 1, wherein the one or more rib (108) is located and extending centrally along a length of the one or more flat portion (106-2 of the one or more cover (104.
10. The safety module (100) as claimed in claim 3, wherein the one or more cover (104) is further connected to the housing (102) through one or more second breakable member (114) that are adapted to break from pressure exerted by the airbag (300) during deployment and correspondingly allow the panels (110-A, 110-B) to pivot to the open position of the cover (104).
11. The safety module (100) as claimed in claim 1, wherein the housing (102) includes a guiding portion adapted to guide the deployment of the airbag (300).
12. The safety module (100) as claimed in claim 1, wherein the housing (102) or the safety module (100) is configured to be installed at predefined positions in the carrier of the vehicle, wherein the carrier is associated with a group comprising a steering wheel, a dashboard, door panels, rear side of seats, lateral sides of the seats, and roof panels of the vehicle.