Airbag Base Plate Attachment via Bendable Tab
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Solution Overview
Problem
Conventional airbag module attachment designs are cumbersome, increasing weight, cost, and assembly complexity due to the use of extra fasteners, rigid hooks, and additional base plates, and are prone to cross-threading and loosening issues, making them less suitable for high-volume, low-cost applications.
Innovation Solution
An airbag assembly featuring a base plate with bendable tabs that securely attach to a cover, eliminating the need for extra fasteners and ensuring proper alignment and retention during deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded studs are used to attach the cover to the base plate, then the cover can be securely retained, but the assembly complexity increases due to cross-threading risks and the need for checking proper assembly
Solution Approach 1:
The patent removes the threaded studs from the attachment mechanism and replaces them with an integrated snap-fit tab system. The tabs are directly formed on the base plate and engage with corresponding features on the cover through elastic deformation, eliminating the need for separate fasteners and the associated assembly complexity of threading and verification.
Solution Approach 2:
The snap-fit tabs provide self-aligning and self-verifying attachment. As the cover is placed on the base plate, the tabs automatically engage with the cover features through elastic deformation, providing tactile and visual confirmation of proper assembly without requiring additional checking steps or specialized tools.
2Reliability
If threaded studs with lock washers or thread binding agents are used, then loosening from vibration is prevented, but the number of parts increases and assembly time is extended
Solution Approach 1:
The patent combines the attachment function into a single integrated snap-fit tab structure that is directly formed on the base plate. This eliminates the need for separate lock washers, thread binding agents, or other anti-loosening components, reducing the total part count while maintaining vibration resistance through the elastic engagement of the tabs.
Solution Approach 2:
The patent replaces the threaded mechanical fastening system with an elastic snap-fit mechanism. The tabs utilize elastic deformation to create a interference fit with the cover, providing vibration resistance through friction and mechanical interlocking without requiring threads, lock washers, or chemical binders.
3Reliability
If conventional attachment designs with extra fasteners and rigid hooks are used, then the cover can be attached to the base plate, but the overall weight of the airbag module increases
Solution Approach 1:
The patent removes extra fasteners, rigid hooks, and additional base plates from the design, retaining only the essential snap-fit tabs integrated into the base plate. This extraction of non-essential components significantly reduces the overall weight of the airbag module while preserving the cover attachment function.
Solution Approach 2:
The patent utilizes flexible snap-fit tabs that can elastically deform during assembly and engagement. These thin, flexible tabs replace heavy rigid hooks and multiple fasteners, achieving the same attachment function with minimal material and weight while maintaining structural integrity during deployment.
4Reliability
If multiple separate components are used for attachment, then the attachment mechanism can be robust, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate attachment components into a single integrated base plate structure with snap-fit tabs directly formed during molding or fabrication. This consolidation eliminates the need for separate fasteners, hooks, and additional base plates, reducing manufacturing steps, assembly operations, and overall production cost while maintaining attachment robustness.
Solution Approach 2:
The snap-fit tabs serve multiple functions: they provide attachment, self-alignment, assembly verification, and vibration resistance. This multi-functionality replaces what would otherwise require multiple specialized components, simplifying the manufacturing process and reducing costs associated with producing, inventorying, and assembling multiple parts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies assembly, reduces weight and cost, and enhances deployment reliability by providing a secure attachment mechanism that prevents detachment and loosening, making it more feasible for high-volume production.
Implementation Method 1
The bendable tab is configured to attach to the cover
Data Source
AI summary
An airbag assembly includes an airbag, an inflator for inflating the airbag, a cover and a base plate. The base plate attaches to the cover such that the base plate is secured on each edge of the base plate and is prevented from detaching. The base plate and cover do not require fasteners or removable pieces. The base plate comprises a bendable tab. The bendable tab is configured to bend over an edge of the cover and secure to the cover by a lip on an end of the bendable tab.