Housing assembly for an air bag and vehicle horn switch

Abstract

An apparatus for enclosing an air bag ( 38 ) on a steering wheel ( 22 ) includes an inner cover ( 34 ) at least partially enclosing the air bag ( 38 ) and having a tear seam central portion ( 50 ) along which the inner cover ruptures upon inflation of the air bag ( 38 ). An outer cover ( 36 ) at least partially encloses the inner cover ( 34 ) and the air bag ( 38 ) and includes a tear seam central portion ( 49 ) with a length substantially equal to the length of the tear seam central portion ( 50 ) in the inner cover ( 34 ). A horn switch ( 58 ) is disposed between the inner and outer covers ( 34 and 36 ) for effecting operation of a horn. The horn switch ( 58 ) includes first and second tear seams ( 64, 65 ) aligned with the tear seam central portions ( 50 and 49 ) in the inner and outer covers ( 34 and 36 ). The first and second tear seams ( 64, 65 ) in the horn switch ( 58 ) have a combined length substantially less than the length of each of the tear seams ( 49 and 50 ).

1. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
 an inner cover having a first wall at least partially enclosing the air bag and including means for defining a first tear seam which extends across said first wall and along which said inner cover ruptures upon inflation of the air bag to enable deployment of the air bag;  
 an outer cover having a second wall at least partially enclosing said inner cover and the air bag and including means for defining a second tear seam which extends across said second wall and along which said outer cover ruptures upon inflation of the air bag to enable deployment of the air bag; and  
 a horn switch disposed between said inner and outer covers for effecting operation of the horn, said horn switch including first and second overlying layers of electrically conductive material and first and second tear seams in said horn switch along which said horn switch ruptures upon inflation of the air bag to enable deployment of the air bag, said first and second tear seams in said horn switch being aligned with said first and second tear seams in said inner and outer covers and having a combined length less than the length of each of said first and second tear seams in said inner and outer covers.  
 
     
     
       2. An apparatus as set forth in  claim 1  wherein said horn switch includes first and second portions located on opposite sides of said first and second tear seams in said horn switch and a pair of spaced apart interconnecting portions interconnecting said first and second portions, said interconnecting portions including said first and second tear seams in said horn switch. 
     
     
       3. An apparatus as set forth in  claim 1  wherein said horn switch includes first and second layers of electrically conductive material, each of said first and second layers having portions located on opposite sides of said first and second tear seams in said inner and outer covers and electrically conductive portions interconnecting said portions located on opposite sides of said first and second tear seams in said inner and outer covers. 
     
     
       4. An apparatus as set forth in  claim 3  wherein said horn switch includes an envelope of electrically insulating material enclosing said first and second layers of said horn switch. 
     
     
       5. An apparatus as set forth in  claim 4  wherein said envelope includes surface means for defining a plurality of openings for receiving fasteners to connect said horn switch to one of said inner and outer covers. 
     
     
       6. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
 an inner cover at least partially enclosing the air bag and including means for defining a first tear seam in said inner cover along which said inner cover ruptures upon inflation of the air bag to enable deployment of the air bag;  
 an outer cover at least partially enclosing said inner cover and the air bag and including means for defining a second tear seam in said outer cover along which said outer cover ruptures in response to inflation of the air bag to enable deployment of the air bag; and  
 a horn switch disposed between said inner and outer covers for effecting operation of the horn, said horn switch including first and second overlying layers of electrically conductive material, said first layer including a first portion with a first tear line aligned with said first and second tear seams in said inner and outer covers, said second layer including a second portion spaced apart from said first portion with a second tear line aligned with said first and second tear seams in said inner and outer covers and spaced apart from said first tear line along a line extending along said first and second tear lines, said horn switch being rupturable along said first and second tear lines upon inflation of the air bag.  
 
     
     
       7. An apparatus as set forth in  claim 6  wherein said first and second tear lines have a combined length less than a length of said first tear seam in said inner cover. 
     
     
       8. An apparatus as set forth in  claim 6  wherein said horn switch includes an envelope of electrically insulating material extending around said first and second layers of said horn switch, said envelope including a first portion extending around said first portion of said first layer and a second portion spaced from said first portion extending around said second portion of said second layer. 
     
     
       9. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
 an inner cover having a first wall at least partially enclosing the air bag, said first wall being movable upon deployment of the air bag;  
 an outer cover having a second wall at least partially enclosing said inner cover and the air bag and including means for defining a tear seam which extends across said second wall and along which said outer cover ruptures upon inflation of the air bag to enable deployment of the air bag; and  
 a horn switch disposed between said inner and outer covers for effecting operation of the horn, said horn switch including first and second overlying layers of electrically conductive material and an envelope of electrically insulating material enclosing said first and second layers, said horn switch including a tear seam along which said horn switch ruptures upon inflation of the air bag to enable deployment of the air bag.  
 
     
     
       10. An apparatus as set forth in  claim 9  wherein said tear seam in said horn switch is aligned with said tear seam in said outer cover. 
     
     
       11. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
   a cover wall having a tear seam along which said cover wall ruptures in response to inflation of the air bag to enable deployment of the air bag; and        a horn switch including first and second overlying layers of electrically conductive material, said first layer including a first portion with a first tear line aligned with said tear seam in said cover wall, said second layer including a second portion which is spaced apart from said first portion and which has a second tear line aligned with said tear seam in said cover wall, said second tear line being spaced apart from said first tear line along a line extending along said first and second tear lines, said horn switch being rupturable along said first and second tear lines upon inflation of the air bag.     
     
     
       12. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
   a cover wall having a tear seam along which said cover wall ruptures in response to inflation of the air bag to enable deployment of the air bag; and        a horn switch including first and second overlying layers of electrically conductive material, said first layer including a first portion with a first tear line aligned with said tear seam in said cover wall, said second layer including a second portion which is spaced apart from said first portion and which has a second tear line aligned with said tear seam in said cover wall, said second tear line being spaced apart from said first tear line along a line extending along said first and second tear lines, said horn switch being rupturable along said first and second tear lines upon inflation of the air bag,        said first and second tear lines having a combined length less than the length of said tear seam in said cover wall.     
     
     
       13. An apparatus for enclosing an air bag on a steering wheel of a vehicle having a horn, said apparatus comprising:
   a cover wall having a tear seam along which said cover wall ruptures in response to inflation of the air bag to enable deployment of the air bag; and        a horn switch including first and second overlying layers of electrically conductive material, said first layer including a first portion with a first tear line aligned with said tear seam in said cover wall, said second layer including a second portion which is spaced apart from said first portion and which has a second tear line aligned with said tear seam in said cover wall, said second tear line being spaced apart from said first tear line along a line extending along said first and second tear lines, said horn switch being rupturable along said first and second tear lines upon inflation of the air bag,        said horn switch including an envelope of electrically insulating material extending around said first and second layers of electrically conducive material, said envelope including a first portion extending around said first portion of said first layer and including a second portion which is spaced from said first portion and which extends around said second portion of said second layer.