Airbag Module Weight Reduction via Segmented Housing
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Solution Overview
Problem
Existing airbag modules mounted on instrument panels are heavy due to their rigid housing, which serves both as a pressure canister and inflator retainer, limiting weight reduction opportunities.
Innovation Solution
The airbag module is redesigned with separate components, including a fabric housing with a guiding function and a retainer, which can be a fabric strip or rigid bracket, to eliminate the need for a rigid housing, allowing for a floating inflator and reduced weight while maintaining protection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid housing is used to retain the inflator and absorb pressure, then the structural strength and pressure absorption capability are improved, but the weight of the airbag module increases
Solution Approach 1:
The patent divides the housing into multiple functional segments: a retaining portion for securing the inflator and a receiving portion for guiding the airbag. This segmentation allows each part to be optimized independently - the retaining portion provides necessary strength while the receiving portion uses lighter material, reducing overall weight while maintaining structural integrity.
Solution Approach 2:
The housing is designed with varying material properties in different regions. The retaining portion uses rigid material with high strength to secure the inflator, while the receiving portion uses lighter material that provides guidance without excessive weight. This local differentiation of material quality optimizes the strength-to-weight ratio throughout the structure.
2Stability of the object's composition
If a rigid housing is used to retain the inflator, then the fixing stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The housing is segmented into a retaining portion and a receiving portion that can be manufactured separately and then assembled. This reduces the complexity of manufacturing a single complex rigid housing while maintaining the stability provided by the retaining portion's inflator fixation features.
Solution Approach 2:
The patent changes the material parameter from uniformly rigid to a combination of rigid and lighter materials in different regions. This parameter change simplifies the overall structure by eliminating the need for a completely rigid housing while maintaining sufficient fixing stability through the strategically placed rigid retaining portion.
3Stress or pressure
If a thick-walled rigid housing is used for pressure absorption, then the pressure containment capability is improved, but the weight and material usage increase
Solution Approach 1:
The housing is divided into regions with different pressure containment requirements. The retaining portion handles the high-stress inflator mounting area, while the receiving portion uses thinner walls since it only needs to guide the airbag, not contain deployment pressures. This segmentation reduces overall material usage and weight.
Solution Approach 2:
Different wall thicknesses and material densities are applied locally based on functional requirements. The retaining portion has higher density and thickness for pressure absorption, while the receiving portion has lower density and thickness for lightweight guidance, optimizing the overall pressure-to-weight ratio.
Data Source
AI summary
The invention relates to an airbag module (10) for being arranged on an instrument panel (5) comprising a fastening portion (22) provided for being arranged on the instrument panel (5), an inflator (16), an airbag (12), a receiving portion (26) for the airbag (12) extending from the inflator (16) to the fastening portion (22) and a retaining portion (24) which is accessible from outside of the receiving portion (26) and serves for retaining the inflator (16). The invention also relates to a subassembly comprising an instrument panel (5) and an airbag module (10) according to any one of the preceding claims, the fastening portion (22) of the airbag module (10) being connected to the instrument panel (5) and a retainer (28) formed separately from the airbag module (10) being provided which is connected to the retaining portion (24) of the airbag module (10).