Airbag Case Injection Molding Wedge Mechanism
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Solution Overview
Problem
Current methods for manufacturing airbag cases with chute channels and nets are inefficient in reducing manufacturing steps and time while ensuring occupant safety, and there is a need to minimize the risk of injury during airbag deployment.
Innovation Solution
A method for injection molding an airbag case using a mold with a wedge mechanism, where a net is arranged in a continuous unit, allowing for the overmolding of the flap and chute channel with a protected third portion forming a hinge, reducing the risk of detachment and optimizing the deployment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the net is folded and maintained by an assembly element before manufacturing the flap and chute channel, then the hinge structure can be formed, but the manufacturing steps and time are increased
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding step. The flap, chute channel, and net assembly are manufactured simultaneously in one mold, eliminating the need for separate folding and assembly steps. This integration reduces manufacturing complexity while maintaining safety through the continuous material structure that forms a reliable sealed zone.
Solution Approach 2:
The injection mold serves multiple functions: it forms the flap, the chute channel, and secures the net assembly all in one operation. The mold includes a wedge mechanism that simultaneously positions the net and creates the sealed zone between the flap and chute channel, demonstrating multi-functionality that reduces both manufacturing steps and potential safety risks.
2Productivity
If the net is folded and maintained by an assembly element, then the hinge structure can be formed, but the manufacturing time is increased
Solution Approach 1:
The patent merges the formation of the hinge structure into the injection molding process itself. The continuous material structure creates the hinge functionality without requiring separate folding and assembly operations, thereby reducing manufacturing time while avoiding increased device complexity.
3Manufacturing precision
If plastic material is injected to manufacture the flap and chute channel, then the sealed zone can be created, but the third portion of the net may be contaminated by injected material
Solution Approach 1:
The mold is segmented into distinct zones: the injection zone for the flap and chute channel, and the protected zone for the third portion of the net. The wedge mechanism creates a physical barrier that segments the mold cavity, preventing injected material from contaminating the net while ensuring proper formation of the sealed zone in the injection area.
Solution Approach 2:
The wedge acts as an intermediary element that mediates between the injection process and the net assembly. It creates a protective barrier that allows the injection of plastic material to form the sealed zone while preventing the material from reaching and contaminating the third portion of the net.
4Object-affected harmful factors
If the wedge is made movable to isolate the third portion of the net, then protection from injected material is achieved, but the mold complexity increases
Solution Approach 1:
The movable wedge serves as an intermediary protective element that can be positioned to isolate the net during injection and then moved away to allow net removal. This simple mechanical movement provides effective protection without significantly increasing overall mold complexity.
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
This method reduces manufacturing steps and time while enhancing safety by creating a sealed zone between the flap and chute channel, providing a protected hinge and minimizing forces opposing airbag deployment, thus reducing the risk of injury.
Implementation Method 1
the wedge is movably mounted in translation with regard to the first matrix between a protective position, wherein the wedge and the matrix close the protective space, and an open position, wherein the wedge and the matrix do not close the protective space
Implementation Method 2
manufacturing the flap and the chute channel by injecting plastic material into the mould, by overmolding plastic material respectively on the second portion of the net and on the first portion of the net
Data Source
AI summary
A method for injection molding of an airbag case comprising a chute channel and a flap, with the chute channel being adapted to receive an airbag. The injection molding is carried out in a mold and comprises the following steps:arranging in the mold a net,manufacturing the flap and the chute channel by injecting plastic matter into the mold, by overmolding plastic matter on the net by manufacturing a continuity of material between the chute channel and the flap, with a portion of the net being isolated from the injected plastic material, in a closed protective space delimited between a wedge mobile and a first matrix of the mold.An airbag case in particular manufactures with such a method and dashboard for a vehicle.