Composite Airbag Cover Break Line With Protective Flap

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Solution Overview

Problem

The challenge lies in effectively sealing composite material panels over airbag devices while ensuring they are releasable during collisions without causing unwanted noise or material leakage, and maintaining high fiber alignment for strength and visual appearance.

Innovation Solution

A composite material panel with a break line is designed to tear along a predetermined path when the airbag deploys, featuring a detachable portion and a tether to manage the panel's movement, and protection flaps to cover edges and prevent airbag puncture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a composite material panel is used to cover the airbag device, then the vehicle weight is reduced, but the panel must be both securely sealed and easily releasable during collision

Engineering Contradiction:

Improvevehicle weightVSAvoidpanel sealing reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The panel is divided into a fixed portion and a detachable portion separated by a break line. The break line creates a controlled separation path that allows the panel to be securely sealed during normal use but easily separated during collision when the airbag deploys

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The break line is pre-formed in the panel during manufacturing, creating a predetermined separation path before the collision occurs. This preliminary preparation ensures that when the airbag deploys, the panel will separate cleanly along the break line without causing unwanted noise or material leakage

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the panel is securely sealed to prevent material leakage, then sealing reliability is improved, but the panel becomes difficult to release during collision

Engineering Contradiction:

Improvepanel sealing reliabilityVSAvoidpanel release ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The panel is segmented into fixed and detachable portions with a break line between them. This segmentation allows the panel to maintain secure sealing during normal use while enabling easy release during collision through controlled separation along the break line

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The detachable portion is extracted from the fixed portion through the break line, allowing the panel to be released during collision. The tether connects these portions and manages their relative movement during deployment

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If the break line is placed close to the aperture for controlled tearing, then the panel separation control is improved, but sharp fragments may puncture the airbag

Engineering Contradiction:

Improvebreak line positioning precisionVSAvoidairbag puncture risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The protection flap is positioned to cover the aperture before the airbag deploys. When the panel tears along the break line, the protection flap is already in place to cushion and protect the airbag from sharp fragments, preventing puncture while allowing controlled separation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The protection flap acts as an intermediary element between the tearing panel and the airbag. It intercepts the sharp fragments generated by the break line tearing and prevents them from reaching and puncturing the airbag

Inventive Principle:

Principle #24Intermediary (Mediator)

4Weight of moving object

If composite material panels are used to reduce vehicle weight, then fuel efficiency is improved, but fiber alignment between separate panels becomes difficult to maintain

Engineering Contradiction:

Improvevehicle weightVSAvoidfiber alignment precision

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

The fixed portion and detachable portion are formed as a single integrated composite panel with the break line incorporated during manufacturing. This merging approach ensures continuous fiber alignment throughout the entire panel, maintaining both strength and visual appearance while enabling controlled separation

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11865992B2Airbag cover

Publication Date: 2024.01.09 MCLAREN AUTOMOTIVE LTD

AI summary

A vehicle comprising: an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through the aperture in the housing when moving from the packed configuration to the expanded configuration; a composite material panel positioned to cover the airbag device, the panel comprising a break line running over the panel, the break line being proximal to the aperture so that when the airbag moves to the expanded configuration the airbag forces the panel to tear along the break line; and a first protection flap, the first protection flap having an initial configuration where the first protection flap is located adjacent the airbag in the packed configuration and a deployed configuration where the first protection flap covers at least one edge of the panel that runs along one side of the break line when the panel has torn due to the airbag moving to the expanded configuration.