Airbag Hanger Tab Anti-Twist Design via Segmented Layers
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Solution Overview
Problem
Existing hanger tabs for airbag cushions face challenges in providing both anti-twisting functionality and adequate performance during off-axis loading, often requiring additional components like anti-twist rods or extrusions, which increase costs, and may not provide sufficient strength or ease of assembly.
Innovation Solution
A single-piece tab made of unitary material with multiple layers, featuring aligned openings and sections of differing layer counts to facilitate sewing and alignment, allowing for anti-twisting functionality without additional components and improved performance during off-axis loading, by extending through a hanger slot and around its head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hanger tabs are used, then the structure is simple, but they provide poor performance with off-axis loading and inadequate anti-twist functionality
Solution Approach 1:
The tab is divided into multiple distinct sections (first section with first plurality of openings, second section with second plurality of openings, third section with slot) that can be independently configured to perform different functions. This segmentation allows the tab to provide anti-twist functionality through specific geometric arrangements while maintaining overall structural integration.
Solution Approach 2:
The invention transitions from a simple planar tab design to a multi-dimensional structure with multiple layers (first layer, second layer, third layer) and multiple sections arranged in specific spatial relationships. This dimensional complexity enables the tab to resist both twisting forces and off-axis loading through its three-dimensional geometry.
2Reliability
If additional components like anti-twist rods or extrusions are added, then anti-twist functionality is improved, but device complexity and cost increase
Solution Approach 1:
The invention merges multiple functions (anti-twist resistance, off-axis loading resistance, and structural coupling) into a single integrated tab component. The tab combines multiple sections, layers, and geometric features that collectively provide anti-twist functionality without requiring separate anti-twist rods or extrusions, thereby reducing the total number of components.
Solution Approach 2:
The tab is designed as a multi-functional component that simultaneously provides anti-twist functionality, off-axis loading resistance, and structural coupling between the airbag cushion and mounting structure. The multiple sections and layers each contribute different functional properties that collectively address multiple performance requirements in a single component.
3Strength
If more layers of material are added to the tab, then strength is improved, but sewing difficulty increases
Solution Approach 1:
The tab is segmented into multiple sections with different numbers of layers (first section, second section, third section) rather than using a uniform multi-layer structure throughout. This segmentation allows the design to provide high strength where needed while maintaining easier manufacturability in other areas, and the aligned openings facilitate consistent stitching through the varied layer configurations.
Data Source
AI summary
Tabs for coupling airbag cushions to hangers and/or vehicles, along with related assembly/manufacturing methods. In some embodiments, the tab may comprise a first section comprising a first plurality of openings and a slot configured to receive a portion of the hanger therethrough, the slot being positioned in between at least a first opening of the first plurality of openings and a second opening of the first plurality of openings. The tab may further comprise a second section comprising a second plurality of openings. In some embodiments the second section may comprise, at least in part, a narrower width than the first section.