Thin airbag module design for overhead applications

A thin overhead airbag system configured to protect occupants of a vehicle from impact, the system comprising:

• a housing assembly having a lower housing, an upper housing, and at least one compressed section which allows the housing assembly to be mountable within a roof of a vehicle;
• an inflatable air bag cushion positioned between the upper housing and the lower housing such that a portion of the cushion is within the at least one compressed section of the housing assembly;
• and
• an inflator in fluid communication with the inflatable air bag cushion.

A method of manufacturing a thin overhead airbag module for installation in a vehicle having an overhead space with a thin transverse profile, said method comprising:

• a. placing an inflator in fluid communication with at least one inflatable airbag cushion configured to protect occupants of a vehicle from impact;
• b. packaging the at least one airbag cushion into a compressible cavity within a housing assembly, the compressible cavity being formed by an upper housing member with a stepped geometry and a lower housing member;
• c. mechanically coupling the upper housing member to the lower housing member;
• and
• d. compressing the housing assembly so that a transverse profile of the housing assembly is less than the transverse profile of the overhead space in the vehicle.