Airbag Package Molding with Living Hinge
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Solution Overview
Problem
Existing airbag packaging methods lack reproducibility and precise mechanical properties, leading to inconsistencies in airbag performance due to errors in positioning during manufacturing.
Innovation Solution
A method involving a plastically deformable sheet of precursor material subjected to heat and pressure within a moulding press to form a self-supporting airbag package with a 'living hinge', eliminating the need for complex temperature regulation and ensuring well-determined mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the package is formed from ductile felt material with first and second package portions located on opposite sides of a folding line, then the package can be made lighter and thinner, but errors in positioning of the package portions will have a noticeable impact on the mechanical properties of the resulting airbag package
Solution Approach 1:
The patent merges the first package portion, second package portion, and hinge into a single integrated component formed from one continuous sheet of precursor material. This eliminates the need for separate positioning of multiple portions, as they are inherently aligned through the single-sheet construction process, thereby resolving the contradiction between lightweight design and positioning precision.
Solution Approach 2:
The patent segments the package into functional regions (first package portion, second package portion, and hinge) that are defined by fold lines within a single continuous sheet. This segmentation allows each region to be optimally designed for its function while maintaining precise relative positioning through the unified sheet structure, avoiding the positioning errors that would result from assembling separate components.
2Device complexity
If the sheet is integrally heated to a required temperature before being placed inside the moulding press, then complex temperature regulation means in the moulding press can be eliminated, but the heating process must be precisely controlled to ensure uniform properties
Solution Approach 1:
The patent applies preliminary action by heating the entire precursor sheet to the required temperature before placing it in the moulding press. This pre-heating step eliminates the need for complex temperature regulation systems within the press itself, as the material is already at the optimal processing temperature when molding begins, thereby simplifying the device while maintaining temperature uniformity.
3Reliability
If the sheet is subjected to pressure to integrally form the shell, lid, and hinge into a continuous three-dimensional shape, then reproducible and reliable mechanical properties are achieved, but the pressure application process becomes more complex
Solution Approach 1:
The patent combines the formation of the shell, lid, and hinge into a single integrated molding process. By forming all components from one continuous sheet in one pressurization step, the process ensures consistent mechanical properties across all parts while eliminating the need for multiple separate forming operations, thereby achieving reliability without excessive complexity.
Solution Approach 2:
The patent utilizes parameter changes by controlling the pressure, temperature, and time parameters during the molding process. By optimizing these parameters for the integrated forming process, the patent achieves reproducible mechanical properties for the entire package structure, including the hinge region, while maintaining a relatively simple single-step process.
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 method achieves reproducible and reliable mechanical properties for the airbag package, enhancing its performance and stability by integrating the shell, lid, and hinge in a single pressurization step, while allowing for the use of ductile fabric materials with flame-retardant properties.
Implementation Method 1
providing a sheet of precursor material, which is plastically deformable when subjected to heat and/or pressure
Implementation Method 2
subjecting the sheet to pressure, thereby integrally forming the shell, the lid, and the hinge, into a continuous (unitary) and self-supporting three-dimensional shape
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
A method for manufacturing an airbag package (20), including: providing a sheet of felt precursor material which is plastically deformable when subjected to predetermined levels of heat and/or pressure; placing the sheet between mould parts; subjecting the sheet to pressure, thereby integrally forming a continuous and self-supporting three-dimensional shape with a shell, a lid, and a hinge. The shell (22) defines an inner compartment (26) for accommodating a rolled-up/folded airbag, and includes a rim (23) at an edge of the compartment. The lid (24) has a second rim (25) configured to engage the shell along said rim so that the lid covers said compartment. The hinge (30) interconnects the shell and the lid along a nominal axis (A), and allows the lid to pivot about said axis and relative to the shell between opened and closed states.