Air bag module assembly

An air bag module assembly for disposition within an automotive vehicle in substantially opposing relation to an occupant to be protected, the air bag module assembly comprising:

• a housing including a bottom wall and side walls extending upwardly from the bottom wall to define a depressed profile storage bin between the side walls;
• a gas emitting inflator disposed at a location within the housing between the side walls;
• and
• an inflatable air bag cushion in fluid communication with the inflator, wherein the air bag cushion is stored in folded relation at least partially within the housing such that a first portion of the air bag cushion is disposed in a multi-layer folded arrangement projecting away from the inflator at least partially across the housing between the side walls in elevated relation to the inflator and wherein a second portion of the air bag cushion is disposed in folded relation within the depressed profile storage bin in substantially side by side adjacent relation to the inflator such that upon activation of the inflator the first portion of the air bag cushion is initially pressurized and projected away from the inflator and such that the second portion of the air bag cushion is thereafter progressively pulled out of the depressed profile storage bin as inflation proceeds.

A method of assembling an air bag module for disposition within an automotive vehicle in substantially opposing relation to an occupant to be protected, the method comprising:

• providing a housing including a bottom wall and side walls extending upwardly from the bottom wall to define a depressed profile storage bin between the side walls;
• placing a gas emitting inflator at a location within the housing between the side walls;
• securing an inflatable air bag cushion in place at fastening locations such that the air bag cushion is in fluid communication with the inflator;
• folding a first portion of the air bag cushion such that the first portion is disposed at least partially across the housing between the side walls in elevated relation to the inflator;
• and
• packing a second portion of the air bag cushion in folded relation within the depressed profile storage bin in substantially side by side adjacent relation to the inflator such that upon activation of the inflator the first portion of the air bag cushion is initially pressurized and projected away from the inflator and such that the second portion of the air bag cushion is thereafter progressively pulled out of the depressed profile storage bin as inflation proceeds.