Airbag Module Tether Tear Mechanism for Controlled Deployment
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Solution Overview
Problem
Current airbag deployment systems require a pre-fold and sewing step before folding, which is time-consuming and variable, especially for out-of-position occupants, and does not effectively reduce the force imparted by the deploying airbag cushion.
Innovation Solution
An airbag module with an internal tether that includes a weakened portion, allowing the pre-folded portion to remain folded during initial inflation and then tear to enable full deployment, eliminating the need for pre-folding and sewing, and providing controlled deployment trajectories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a pre-fold and sewing step is used before folding the airbag, then the pre-fold position is held in place, but the process becomes time-consuming and variable
Solution Approach 1:
The airbag is pre-folded and tucked into a storage configuration before deployment, eliminating the need for sewing steps. The pre-folded state is maintained through the stored configuration itself, allowing rapid deployment without time-consuming assembly operations.
Solution Approach 2:
The sewing step is completely removed from the process. Instead of using thread to hold the pre-fold position, the invention extracts the sewing operation and replaces it with a mechanical pre-folded storage configuration that maintains position through geometry rather than fastening.
2Stability of the object's composition
If a pre-fold is sewn to hold position, then the pre-fold remains in place during storage, but the sewing thread must be designed to tear away adding complexity
Solution Approach 1:
The sewing thread and associated tearing mechanism are completely extracted from the system. The invention replaces this complex fastening and release mechanism with a simple pre-folded storage configuration that uses the airbag's own geometry to maintain position during storage and deployment.
Solution Approach 2:
The airbag structure itself provides the positioning function during storage through its pre-folded configuration, eliminating the need for external sewing threads. The design is self-sufficient, using its own form to maintain the required geometry without additional components.
3Speed
If the airbag deploys fully without control, then deployment speed is maximized, but the force imparted onto out-of-position occupants increases
Solution Approach 1:
The airbag is pre-folded into a compact storage configuration that controls the deployment trajectory. This preliminary folding creates a controlled expansion path that directs the airbag away from out-of-position occupants during initial deployment, reducing harmful forces while maintaining overall deployment speed.
Solution Approach 2:
The airbag is divided into functional zones through pre-folding, creating different deployment characteristics in different regions. The pre-folded configuration segments the deployment trajectory to protect out-of-position occupants while allowing full deployment for properly positioned occupants.
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
Simplifies the folding process, reduces variability, and ensures consistent deployment, providing tailored protection for out-of-position occupants by controlling the force and trajectory of the airbag, thereby enhancing safety and manufacturing efficiency.
Implementation Method 1
an inflator configured to provide gas to inflate the airbag. The inflatable chamber is configured to be inflated by a process that includes providing gas from the inflator into the chamber
Implementation Method 2
the tether includes a weakened portion between the ends of the tether. During a final stage of the inflation process the weakened portion tears so that the tether separates
Data Source
AI summary
An airbag module including an inflatable airbag and an inflator. The airbag is formed by a main panel and a pair of side panels and deploys into a position to contact the occupant. The airbag includes a tether connected to the main panel at one end and is anchored proximate to the inflator at the other end. Prior to inflation, the airbag includes a pre-folded portion adjacent to the tether. The airbag is configured so that during an initial stage of the inflation process the tether is fully extended and the pre-folded portion remains folded and during a final stage of the inflation process the tether separates into at least two portions thereby allowing the pre-folded portion to unfold and the airbag to fully deploy.