Foam-in-place Interior Panel Airbag Chute Assembly
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Solution Overview
Problem
Existing foam-in-place interior panels for motor vehicles with integrated airbag doors are complex to assemble due to the use of multiple parts and threaded fasteners, which complicates the accommodation of airbag devices.
Innovation Solution
An airbag chute-door assembly is mounted to the substrate using locking tabs and rib/tab features, eliminating the need for threaded fasteners, and featuring an expansion mechanism that allows the chute wall to move from a nominal to an expanded position for easy airbag module mounting, with a skin covering and foam layer formed over the assembly to create a seamless integrated airbag door.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular airbag door assembly with threaded fasteners is used, then airbag device can be mounted securely, but assembly complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The airbag chute-door assembly is merged with the substrate by integrating locking tabs directly into the substrate structure and rib/tab features into the chute wall. This combination eliminates the need for separate threaded fasteners and multiple assembly steps, reducing device complexity while maintaining secure mounting through the integrated locking mechanism.
Solution Approach 2:
The threaded fasteners and complex assembly mechanisms are extracted from the design. The invention removes these unnecessary components by implementing a simplified direct-locking system where the chute wall locks directly to the substrate through integrated features, reducing assembly complexity without compromising mounting reliability.
2Adaptability or versatility
If multiple parts and threaded fasteners are used, then airbag device can be accommodated, but manufacturing efficiency decreases
Solution Approach 1:
Multiple separate parts (substrate, airbag chute-door assembly, locking mechanisms) are merged into an integrated structure. The substrate and chute-door assembly are combined with built-in locking tabs and rib features, eliminating the need for separate fasteners and reducing the number of components that need to be manufactured and assembled, thereby improving manufacturing efficiency.
3Ease of operation
If expansion feature is added to chute wall, then airbag module mounting is facilitated, but structural complexity increases
Solution Approach 1:
The chute wall incorporates an expansion feature that allows it to dynamically change shape during the mounting process. The chute wall can expand outward to create clearance for the airbag module to be positioned, then return to its nominal position to lock securely. This dynamic behavior facilitates easy mounting while the expansion mechanism is integrated into the existing chute wall structure, minimizing additional complexity.
Data Source
AI summary
Interior panels having integrated airbag doors for motor vehicles are provided. In one example, an interior panel comprises a substrate having outer and inner surfaces and an opening extending therethrough. An airbag chute-door assembly is mounted to the substrate and comprises a chute wall that at least partially surrounds an interior space. The chute wall is configured for stowing an airbag module. The chute wall defines an expansion feature that facilitates moving sections of the chute wall for assembling the airbag module to the chute wall. A door flap portion is pivotally connected to the chute wall and at least partially covers the opening. A perimeter flange extends from the chute wall and has a flange section that overlies the outer surface of the substrate. A skin covering extends over the substrate and a foam is disposed between the skin covering and the substrate.