Airbag Cover Flap Hinge Using Self-Reinforced Composite
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Solution Overview
Problem
Existing airbag covers are complex to manufacture due to the need for multiple materials and additional components like threads or fabrics, which complicates the production process.
Innovation Solution
A self-reinforced thermoplastic composite material consisting of multiple layers of thermoplastic polypropylene or polyester, with alternating reinforcing layers of polypropylene or polyester strips, fibers, or threads, simplifying the manufacturing process by using a single type of material and eliminating the need for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional threads or fabrics are used in the hinge area to prevent tearing, then the security against tearing off is improved, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent uses a composite material structure consisting of a thermoplastic cover material combined with reinforcement layers made of textile material, metal foil, or plastic foil. These reinforcement layers are integrated into the cover material at the hinge area to provide tearing resistance without requiring separate additional threads or fabrics, thus reducing device complexity while maintaining reliability.
Solution Approach 2:
The reinforcement layers are merged with the cover material to form an integrated structure. The reinforcement layers are positioned between the cover material and the airbag, creating a unified component that provides both covering and tearing resistance functions simultaneously, eliminating the need for separate securing mechanisms.
2Reliability
If multiple materials and additional components are used, then the security against tearing off is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The patent integrates reinforcement layers directly into the thermoplastic cover material during the molding process. The reinforcement layers (textile material, metal foil, or plastic foil) are positioned between the cover material and airbag, allowing the entire structure to be manufactured as a single integrated component, significantly simplifying the manufacturing process compared to assembling multiple separate components.
Solution Approach 2:
The thermoplastic cover material itself provides the securing function through its integration with the reinforcement layers. The material structure is designed to automatically prevent tearing at the hinge area without requiring external securing mechanisms or additional processing steps, making the manufacturing process more straightforward.
3Weight of moving object
If the cover material is made thinner to reduce weight, then the weight is reduced, but the breaking strength and impact resistance deteriorate
Solution Approach 1:
The patent uses a composite structure where thin thermoplastic cover material is combined with reinforcement layers (textile material, metal foil, or plastic foil). This composite construction allows the cover to remain thin and lightweight while the integrated reinforcement layers provide the necessary breaking strength and impact resistance that would otherwise require much thicker material.
Solution Approach 2:
The reinforcement layers are strategically positioned at specific locations where strength is most needed, particularly at the hinge area and between the cover material and airbag. This localized reinforcement allows the overall cover to remain thin and lightweight while providing enhanced strength exactly where required, rather than uniformly thickening the entire cover.
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 results in an airbag cover that is lightweight, thermally deformable, highly resistant to impact and abrasion, environmentally friendly, and easy to produce, with enhanced breaking strength and mobility of the flap without tearing, while maintaining security against detachment.
Implementation Method 1
A heated blade (hot blade) is preferably used to create the fold(s), the groove(s) or the channel(s), which is pressed into the panel in the region of the hinge and thereby deforms the thermoplastic material, the material can also be partially or fully heated prior to deformation.
Implementation Method 2
the composite material additionally being protected from deformation by the sword can still be heated
Implementation Method 3
When pressure is applied and heat is applied, all the layers fuse into a single sheet that consists only of layers of polypropylene or polyester.
Data Source
AI summary
The invention relates to an airbag cover with at least one flap, which is bounded in the cover material by the predetermined breaking lines forming the flap edges and a hinge edge, wherein the cover material is a self-reinforced thermoplastic composite material comprising several superimposed layers of thermoplastic polypropylene or polyester, wherein layers of homogeneous polypropylene film, copolymer-containing polyolefin film, homogeneous polyester film or copolymer-containing polyester film alternate with reinforcing layers in which either the polypropylene or the polyester is in tape, fiber or thread form, or in which the reinforcing layers comprise polypropylene or polyester tapes and/or polypropylene or polyester fibers and/or polypropylene or polyester threads.