Bag folding system

A method of automatically folding an air bag having an end coupled to a retainer;

• an opposed distal end and pleats formed therebetween, said method comprising the steps of:
• providing elongated pleat holding arms positioned to receive the bag adjacent the distal end and extending from the distal end toward the retainer;
• flattening and narrowing the bag and, using the elongated pleat holding arms, holding the bag with the elongated pleat holding arms extending from the distal end parallel with the pleats;
• providing a first plurality of upright blades individually movable between a normal lowered position and a raised position and a second plurality of upright blades spaced vertically above the first plurality and individually movable between a normal raised position and a lowered position, the first plurality and the second plurality being further positioned with the blades interdigitated in the raised and lowered positions, respectively;
• fixing the retainer with the bag positioned between the first and second pluralities of blades and holding the bag with the elongated pleat holding arms adjacent the distal end while allowing the distal end to gradually move toward the retainer;
• and
• forming undulating folds in the bag between the retainer and the distal end by moving a blade of the first plurality of blades into the raised position, moving a blade of the second plurality of blades into the lowered position, and alternately and individually moving each of remaining blades in the first and second pluralities into the raised and lowered positions, respectively, until all of the blades in the first and second pluralities have been moved, while allowing the distal end of the bag to gradually move between the elongated pleat holding arms toward the retainer as each undulating fold is formed.

Apparatus for automatically folding an air bag having an end coupled to a retainer and an opposed distal end, said apparatus comprising:

• elongated pleat holding arms positioned to fit within horizontal pleats in the bag extending from the distal end of the bag substantially to the retainer and to hold the distal end of the bag for limited sliding movement in a horizontal direction to allow the distal end to gradually move toward the retainer as undulating folds are formed in the bag;
• a first plurality of upright blades individually movable between a normal lowered position and a raised position and a second plurality of upright blades spaced vertically above the first plurality and individually movable between a normal raised position and a lowered position, the first plurality and the second plurality being further positioned with the blades interdigitated in the raised and lowered positions, respectively;
• a clamp positioned to receive the retainer therein with the bag positioned between the first and second pluralities of blades while holding the bag adjacent the distal end;
• and
• actuating means for moving each blade of the first plurality of blades into the raised position and alternately and individually moving each blade of the second plurality of blades into the lowered position to form undulating folds in the bag while the distal end of the bag gradually moves toward the retainer as each undulating fold is formed.