Airbag Cushion Diffusor-Tether Layout for Lower Seam Stress
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing airbag cushions face challenges in ease of production, deployment, protection, and robustness, particularly in reducing seam-related breakages and force peaks during deployment.
Innovation Solution
A flexible diffusor-and-tether arrangement is introduced, where the diffusor section is connected to the back panel and the tether section extends to the front panel, distributing forces and providing additional elasticity through slits, and an inner element connection is used for assembly, reducing seam stress and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a combined diffusor- and tether arrangement is used with seams connecting tethers to panels, then the number of seams is reduced, but the risk of seam breakage increases due to concentrated force
Solution Approach 1:
The tether element is segmented into multiple parallel tether sections (first tether section, second tether section, etc.) distributed across the diffusor element. This segmentation distributes the mechanical load from the front panel across multiple connection points to the back panel, reducing the stress concentration on any single seam and thereby reducing the risk of seam breakage while maintaining the reduced seam count advantage.
Solution Approach 2:
The patent applies different structural qualities to different regions: the diffusor element provides gas distribution functionality, while the multiple parallel tether sections provide structural support and force distribution. Each tether section is specifically positioned to handle local force concentrations, creating localized quality variations that optimize both reliability and seam reduction.
2Device complexity
If traditional tether arrangements are used, then deployment structure is simple, but force peaks during deployment cause connection breakage
Solution Approach 1:
The single tether connection is segmented into multiple parallel tether sections extending from the diffusor element to the front panel. This segmentation distributes the deployment forces across multiple connection points, reducing force peaks at any single connection while maintaining structural integrity during deployment.
Solution Approach 2:
The multiple parallel tether sections are arranged to provide beforehand cushioning against force peaks during deployment. The distributed configuration acts as a cushioning system that absorbs and distributes impact forces before they can concentrate on any single connection point, preventing breakage before it occurs.
3Reliability
If multiple separate diffusor and tether elements are used, then functionality is achieved, but manufacturing complexity and seam count increase
Solution Approach 1:
The patent merges the diffusor element and tether elements into a single integrated combined diffusor- and tether arrangement. The tether sections are directly formed as part of the diffusor element structure, eliminating the need for separate components and multiple seams. This merging maintains both gas guidance and tethering functions while significantly simplifying manufacturing.
Solution Approach 2:
The diffusor element is designed with multi-functionality: it serves both as a gas distribution component and as a structural element that directly forms the tether sections. This universal design allows a single component to perform multiple functions (gas guidance + tethering + force distribution), reducing the total number of parts and simplifying manufacturing processes.
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 enhances the airbag cushion's robustness and ease of production by distributing forces, reducing the risk of seam breakages and force peaks, while ensuring effective gas guidance and early deployment in critical areas.
Implementation Method 1
a flexible diffusor element covering the inflator opening of the back panel in order to protect the cushion from the gases produced by the inflator and also to guide said gases within the cushion
Implementation Method 2
the force that is exerted from the front panel via the diffusor and tether element into the back panel is distributed over a large area
Implementation Method 3
In order to add some elasticity to the diffusor section, at least one opening, especially in the form of a slit pointing towards the tether section, can be provided in the diffusor section adjacent to the tether section
Data Source
AI summary
An airbag cushion comprising a back panel having an inflator opening, a front panel connected to the back panel by an edge connection, and a flexible diffusor- and tether arrangement having a diffusing function and tethering function. The diffusor section spans over the inflator opening and is connected with the back panel via a back panel connection having a first and second end point, such that the diffusor section has a first outlet region extending between the first and second end point and the back panel has a first outlet region extending between the first and second end point, such that a first gas outlet is formed between the first outlet region of the diffusor section and the first outlet region of the back panel. The tether section extends from a first end region connected to the diffusor section to a second end region connected to the front panel.