3D Air Bag Panel Sewing for Lower Deployment Load
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Solution Overview
Problem
Existing three-dimensional air bags face manufacturing challenges due to complex sewing methods that lead to defects and high rigidity, which result in excessive load on vehicle interior structures and occupants during deployment.
Innovation Solution
A three-dimensional air bag design that combines three-dimensional sewing and plane sewing, with distinct sewn portions on the main and side panels, allowing for easier manufacturing and reduced load on occupants and vehicle structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If three-dimensional sewing is used to form gently curved surfaces, then the air bag applies less load to occupants and vehicle interior structures, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The air bag is divided into multiple panels (front panel, rear panel, left side panel, right side panel) that are sewn together to form a three-dimensional structure. This segmentation allows each panel to be manufactured separately with standard sewing processes, while the assembled structure provides the desired gently curved surfaces that reduce load on occupants and vehicle interiors.
Solution Approach 2:
The invention transitions from two-dimensional flat panels to a three-dimensional assembled structure. By sewing multiple panels together in three-dimensional space, the air bag achieves gently curved surfaces that conform to the vehicle interior shape, reducing the harmful load effect while using standard manufacturing processes for each panel.
2Object-affected harmful factors
If three-dimensional sewing is used to create curved surfaces, then the air bag provides better protection with gentler contact, but the manufacturing time and productivity decrease
Solution Approach 1:
The air bag is divided into multiple panels that can be manufactured independently using standard sewing processes, improving manufacturing productivity. The segmented panels are then assembled to form the three-dimensional structure with gently curved surfaces that reduce impact force on occupants during deployment.
Solution Approach 2:
The panels are prepared and sewn separately in advance using standard manufacturing processes, allowing for efficient production. The preliminary preparation of individual panels enables faster assembly and reduces overall manufacturing time while maintaining the gentle curved surface characteristics.
3Shape
If complex three-dimensional sewing is used, then the air bag achieves desired gentle curved surfaces, but manufacturing defects increase
Solution Approach 1:
The air bag structure is segmented into multiple panels with clearly defined edges and attachment lines. This segmentation simplifies the sewing process for each panel by providing clear alignment references, reducing manufacturing defects while achieving the desired three-dimensional curved surface shape through assembly.
Solution Approach 2:
Different regions of the air bag are constructed with locally optimized sewing patterns. The panels are designed with specific geometric features that facilitate accurate alignment and sewing in critical areas, ensuring high manufacturing precision for the curved surfaces while maintaining overall structural integrity.
Data Source
AI summary
A three-dimensional air bag includes a first three-dimensional sewn portion in which the main panel and the first side panel portion are sewn together, and a second three-dimensional sewn portion in which the main panel and the second side panel portion are sewn together. A part of the first three-dimensional sewn portion and a part of the second three-dimensional sewn portion are located at an upper surface of the deployed and inflated air bag. A shape of the first three-dimensional sewn portion of the main panel in a natural state is different from a shape of the first three-dimensional sewn portion of the first side panel portion in a natural state. A shape of the second three-dimensional sewn portion of the main panel in the natural state is different from a shape of the second three-dimensional sewn portion of the second side panel portion in a natural state.