Bag folding system

Abstract

An automated system is disclosed for folding vehicle air bags so that a small folded-bag profile and a desirable bag deployment pattern results. A machine having numerous moveable arms is controlled by a controller. An edge folding assembly (EFA) of the machine has five arms, including a center arm, two outer blades, and two outwardly facing U-channel forks, which reside between respective outer blades and the center arm. The EFA moves forward so that all of its five arms engage an unfolded air bag. The forks then raise upward to a level at which the outer blades are aligned with a gap between tines in the forks. The outer blades mesh with this gap causing two pleats to be formed in the edge of the bag. Pleat clamps then move inwardly sideways to engage the two pleats and form a third pleat. Then, the EFA is removed from the bag. The pleat clamps clamp top and bottom sections of the bag together while tightly gripping the pleats. The bag is then inflated, except that the pleat clamps prevent inflation of the pleated section. Next, the pleat clamps move closer together to poke the pleats into the center of the otherwise inflated bag. The bag is then deflated, and the pleat clamps are withdrawn from the bag.

What is claimed is: 
     
       1. A method of automatically folding an air bag having top and bottom sections, said folding achieving a folded-bag profile suitable for vehicular installation along with an effective bag deployment upon a crash of said vehicle, said method comprising the steps of: clamping said top and bottom sections together proximate an edge portion of said bag to substantially restrict inflation of said edge portion, said clamping step leaving a central portion of said bag unclamped;   inflating said central portion of said bag to separate said top section from said bottom section; .[.and.].   .Iadd.limiting separation of said top section from said bottom section; and .Iaddend.   inserting said clamped edge portion into said central portion between said top and bottom sections.   
     
     
       2. A method as claimed in claim 1 additionally comprising, prior to said clamping step, the step of forming a first pleat in said edge portion of said bag so that said clamping step substantially prevents bag inflation proximate said first pleat. 
     
     
       3. A method as claimed in claim 2 wherein said bag cooperates with a fork having first and second tines, each having entrance edges, spaced apart by a first gap and with a blade having a leading edge and being spaced apart from said first and second tine entrance edges by a second gap, and said first pleat forming step comprises the steps of: extending said edge portion of said bag through said second gap; and   moving said blade into said first gap to tuck said bag into said first gap and form said first pleat at said leading edge of said blade.   
     
     
       4. A method as claimed in claim 3 additionally comprising the step of removing said fork and said blade from said bag. 
     
     
       5. A method as claimed in claim 4 wherein said removing step retracts said blade from said first gap before said fork is removed from said bag. 
     
     
       6. A method as claimed in claim 4 comprising the step of positioning, prior to removing said fork from said blade, a clamp having first and second spaced apart fingers so that said first and second fingers reside on opposing sides of said fork. 
     
     
       7. A method as claimed in claim 6 wherein said clamping step comprises the step of urging said first and second fingers toward one another. 
     
     
       8. A method as claimed in claim 2 additionally comprising, prior to said clamping step, the step of forming a second pleat in said edge portion of said bag so that said clamping step substantially prevents bag inflation proximate said second pleat. 
     
     
       9. A method as claimed in claim 8 wherein said bag cooperates with a fork having first and second tines, each having entrance edges, spaced apart by a first gap and with a blade having a leading edge and being spaced apart from said first and second line entrance edges by a second gap, and said method additionally comprises the steps of: extending a first edge portion of said bag through said second gap;   juxtaposing a second edge portion of said bag with said first line of said fork; and   moving said blade into said first gap to tuck said bag into said first gap and form said first pleat at said leading edge of said blade and said second pleat at said entrance edge of said first tine.   
     
     
       10. A method as claimed in claim 1 wherein said clamping step is performed by a clamp having first and second fingers clamped together from opposing sides of said edge portion of said bag, and said inserting step comprises the step of moving said clamp toward said central portion of said bag. 
     
     
       11. A method as claimed in claim 10 wherein said first and second fingers impose a clamping force on said bag, and said method additionally comprises, after said inserting step, the steps of: deflating said bag: removing said clamping force between said fingers and said bag: and   moving said clamp away from said central portion of said bag to disengage said clamp from said bag.   
     
     
       12. An apparatus for automatically folding an air bag having top and bottom sections, an edge portion, and a central portion, said folding achieving a folded-bag profile suitable for vehicular installation along with an effective bag deployment upon a crash of said vehicle, said apparatus comprising: a pleat clamp for clamping said top and bottom sections of said bag together proximate said edge portion of said bag to substantially restrict inflation of said edge portion;   pneumatic means, coupled to said central portion of said bag, for inflating said central portion of said bag to separate said top section from said bottom sections;   means, coupled to said pleat clamp, for inserting said clamped edge portion into said central portion between said top and bottom section; and   control means for coordinating operation of said pleat clamp, inflating means, and inserting means.   
     
     
       13. An apparatus as claimed in claim 12 additionally composing, means, coupled to said control means, for forming a first pleat in said edge portion of said bag. 
     
     
       14. An apparatus as claimed in claim 13 wherein said first pleat forming means comprises: a fork having first and second tines, each having entrance edges, spaced apart by a first gap;   a blade having a leading edge and being spaced apart from said first and second line entrance edges by a second gap;   means for extending said edge portion of said bag through said second gap; and   means for moving said blade into said first gap so that, when said edge portion of said bag is extended through said second gap, said bag is tucked into said first gap, and said first pleat is formed at said leading edge of said blade.   
     
     
       15. An apparatus as claimed in claim 12 wherein said pleat clamp comprises: first and second fingers; and means, responsive to said controller, for clamping said first and second fingers together from opposing sides of said edge portion of said bag.   
     
     
       16. An apparatus as claimed in claim 12 wherein said air bag has a second edge portion on an opposing side of said central portion from said edge portion, and said apparatus additionally comprises: a second pleat clamp, coupled to said control means, for clamping said top and bottom sections of said bag together proximate said second edge portion of said bag to substantially restrict inflation of said second edge portion:   means, coupled to said second pleat clamp and said controller, for inserting said clamped second edge portion into said central portion between said top and bottom section.   
     
     
       17. An apparatus as claimed in claim 12 wherein said pneumatic means additionally deflates said air bag. 
     
     
       18. A method of automatically folding an air bag having top and bottom sections, said folding achieving a folded-bag profile suitable for vehicular installation along with an effective bag deployment upon a crash of said vehicle, said method comprising the steps of: spacing a fork having first and second tines, each having entrance edges, apart by a first gap from a blade having a leading edge, said spacing positioning said blade leading edge apart from said first and second tine entrance edges by a second gap;   extending a first section of an edge portion of said bag through said second gap;   juxtaposing a second section of said edge portion of said bag with said first tine of said fork; and   moving said blade into said first gap to tuck said first section of said bag into said first gap and form a first pleat at said leading edge of said blade and a second pleat at said entrance edge of said first tine;   clamping said top and bottom sections of said bag together proximate said edge portion of said bag to substantially restrict inflation of said edge portion, said clamping step leaving a central portion of said bag unclamped;   inflating said central portion of said bag to separate said top section from said bottom section;   .Iadd.limiting separation of said top section from said bottom section; .Iaddend.   inserting said clamped edge portion into said central portion between said top and bottom sections; and   deflating said bag.   
     
     
       19. A method as claimed in claim 18 comprising the step of positioning, prior to said clamping step, a clamp having first and second spaced apart fingers so that said first and second fingers reside on opposing sides of said fork, bag, and blade. 
     
     
       20. A method as claimed in claim 19 additionally comprising, after said positioning step, the steps of: first, retracting said blade from said first gap to disengage said blade from said bag:   second, retracting said fork from said bag; and third, removing said blade and said fork from within said clamp. .Iadd.   
     
     
       21.  An apparatus as claimed in claim 12, additionally comprising limiting means for limiting separation of said top section from said bottom section. .Iaddend. .Iadd.22. A method as claimed in claim 11 additionally comprises, after said inserting step, the steps of: exerting a downwardly directed force onto said bag as said bag is deflated to a predetermined configuration; and   retaining said bag in substantially the same configuration with said downwardly directed force, as said clamp is moved away from said central   
     
     
        portion of said bag. .Iaddend. .Iadd.23.  An apparatus as claimed in claim 12 additionally comprising means for exerting a downwardly directed force onto said bag to assist in deflating said bag, and to retain said bag during removal of said pleat clamp. .Iaddend. .Iadd.24. A method as claimed in claim 18 additionally comprises, after said inserting step, the steps of: exerting a downwardly directed force onto said bag as said bag is deflated to a predetermined configuration; and   retaining said bag in substantially the same configuration with said downwardly directed force, as said clamp is moved away from said central portion of said bag. .Iaddend.