Airbag Flap Connection via Plastic-Molded Intermediate Layer
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Solution Overview
Problem
Existing airbag arrangements have complex and costly manufacturing processes due to the need for separate work steps and expensive connection methods, such as screwing or gluing, to secure the airbag flap to the firing channel.
Innovation Solution
Incorporating a plastic-impermeable intermediate layer between the airbag flap and the holding means, which is bonded to the carrier, allowing for a connection to be formed during plastic molding, and using a permeable holding means to ensure a strong and reliable connection without altering the material properties of the holding means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first end section is connected to the airbag flap by screwing or gluing, then a reliable connection is achieved, but the manufacturing process becomes complex and costly with separate work steps
Solution Approach 1:
The patent combines the connection of the first end section to the airbag flap with the formation of the carrier in a single plastic molding operation. The plastic material simultaneously forms the carrier structure and creates the material connection with the first end section, eliminating separate screwing or gluing work steps while maintaining connection reliability
Solution Approach 2:
The plastic material acts as an intermediary that bonds the first end section to the airbag flap during the carrier formation process. This plastic intermediary creates a reliable material connection without requiring additional mechanical fasteners or adhesives applied in separate steps
2Strength
If plastic is used for overmoulding to connect the holding means, then a strong connection is formed, but the plastic may penetrate and cohesively connect adjacent subsections of the holding means, altering its material properties
Solution Approach 1:
The plastic-impermeable intermediate layer acts as a mediator between the plastic material and the holding means. It allows the plastic to form strong connections with the first and second end sections while preventing penetration into the middle section, thus preserving the holding means' material properties and functionality
Solution Approach 2:
The patent applies different properties to different parts of the holding means: the first and second end sections are made permeable to plastic for strong connection, while the middle section is protected by an impermeable intermediate layer to maintain its original material properties. This local differentiation resolves the contradiction between connection strength and functional reliability
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 simplifies the manufacturing process, reduces costs, and provides a reliable connection between the airbag flap and the carrier, ensuring the holding means remains intact during deployment.
Implementation Method 1
a plastic-impermeable intermediate layer (20) which is arranged either between the underside and the adjoining section or between at least two of the overlapping sections and which is bonded to the carrier
Implementation Method 2
the plastic forming the carrier typically at least partially penetrates at least the first end section
Data Source
Figure 1
Figure 2a~2d
Figure 3
AI summary
The invention relates to an airbag arrangement (1) having at least one airbag flap (4) which covers a firing channel (3), is composed of plastic and has a visible face (6), which faces a vehicle interior, and a support (5) which forms a lower face which is averted from the visible face (6), and also having a holding means (9) which is connected to the support (5) and has a first end section (10) which is at least partially inserted into the support (5), and a second end section (11) which is connected to a plastic support (12) which surrounds the airbag flap (4), and comprises a central section (13) between the first and second end sections (10, 11), wherein the central section (13) has at least three overlapping subsections (14, 15, 16), and at least one subsection (14) bears against the lower face of the airbag flap (4) or of the surrounding plastic support (12). In this case, a plastic impermeable intermediate layer (17) is arranged between the lower face and the adjoining subsection (14) or between at least two of the overlapping subsections (14, 15, 16), wherein the intermediate layer (17) is cohesively connected to the support (5) or to the surrounding plastic support (12).