Overhead airbag deployment apparatus and method

An overhead airbag assembly configured to be installed proximate a roof of a vehicle, the roof having a header having a generally lateral orientation, the overhead airbag assembly comprising:

• an airbag module attachable to the roof, rearward of the header, the airbag module having a cushion configured to inflate to protect an occupant of the vehicle from impact;
• and
• a headliner having a forward edge configured to be coupled to the header such that the headliner extends underneath the airbag module to conceal the airbag module from the occupant, wherein the headliner comprises a groove having a generally lateral orientation, wherein the groove cooperates with the lateral edge and the forward edge to form a deployment door configured to pivot open at the groove to facilitate emergence of the cushion.
• wherein the headliner is configured to at least partially detach from the header to permit inflation of the cushion between the headliner and the header.

A headliner assembly operable with an airbag module attached to a roof of a vehicle, wherein the airbag module comprises a cushion configured to inflate to protect an occupant of the vehicle from impact, the headliner assembly comprising:

• a headliner configured to extend underneath the airbag module to conceal the airbag module from the occupant, the headliner further comprising a lateral edge configured to be positioned proximate a central, forward portion of the roof and a groove having a generally lateral orientation, wherein the groove cooperates with the lateral edge and the forward edge to form a deployment door configured to pivot open at the groove to facilitate emergence of the cushion;
• and
• a tether attached to the headliner and configured to be attached to the roof;
• wherein the tether has a length selected to permit sufficient motion of the headliner away from the roof to permit emergence of the cushion forward of the headliner and to limit motion of the headliner toward the occupant.

A frangible fastener configured to releasably attach a headliner to a roof of a vehicle such that the headliner is able to open to permit deployment of an airbag module, the airbag module comprising a cushion configured to inflate to protect an occupant of the vehicle from impact, wherein the headliner comprises a lateral edge configured to be positioned proximate a central, forward portion of the roof and a groove having a generally lateral orientation, wherein the groove cooperates with the lateral edge and the forward edge to form a deployment door configured to pivot open at the groove to facilitate emergence of the cushion, the frangible fastener comprising:

• a roof portion configured to engage the roof;
• a headliner portion configured to engage the headliner;
• and
• frangible portion between the roof portion and the headliner portion, wherein the frangible portion is configured to permit separation of the roof portion from the headliner portion in response to deployment of the airbag module.

A method for installing a headliner assembly in a vehicle, the headliner assembly comprising a central console and a headliner, the vehicle comprising a roof having a header having a generally lateral orientation, the vehicle having an airbag module attached to the roof rearward of the header, the airbag module having a cushion configured to inflate to protect an occupant of the vehicle from impact, the method comprising:

• disposing a lateral edge of the headliner proximate a central console;
• attaching peripheral edges of the headliner to peripheral edges of the roof such that the headliner extends underneath the airbag module to conceal the airbag module from the occupant;
• and
• attaching the central console to a central, forward portion of the roof;
• wherein, upon attachment of the central console to the central, forward portion, the lateral edge is attached to the central console such that at least a portion of the lateral edge is removable from the central console to permit the headliner to open toward the vehicle occupant along the lateral edge to permit emergence of the cushion forward of the headliner.

A method for deploying an overhead airbag in a vehicle comprising a roof having a header having a generally lateral orientation, an airbag module attached to the roof rearward of the header, and a headliner having a forward edge attached to the header such that the headliner extends underneath the airbag module to conceal the airbag module from an occupant of the vehicle, and wherein the headliner further comprises a lateral edge configured to be positioned proximate a central, forward portion of the roof and a groove having a generally lateral orientation, wherein the groove cooperates with the lateral edge and the forward edge to form a deployment door configured to pivot open at the groove to facilitate emergence of the cushion, the method comprising:

• commencing inflation of the cushion to exert pressure on the headliner;
• detaching the forward edge from the header in response to the pressure;
• and
• continuing inflation of the cushion to induce the cushion to extend between the headliner and the header to obtain a position forward of the occupant to protect the occupant from impact.