Inflatable Cushion Tether Mounting for Airbag Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing airbag module assembly methods require complex and costly retainer rings for securing inflatable cushions to housings, particularly in passenger side modules, which increase manufacturing costs and assembly time, and may lack lateral support for the cushion.
Innovation Solution
The use of a first tether with a cushion securement end and a mounting end, where the mounting member is capable of pivotal movement and is folded to define a mounting member that can be positioned between orthogonal and parallel positions, allowing secure attachment to the housing without the need for additional fasteners or tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal retainer ring with studs is used to secure the inflatable cushion to the housing, then the cushion is robustly secured, but the manufacturing cost and assembly time increase
Solution Approach 1:
The patent removes the complex metal retainer ring from the assembly and extracts only the essential function of securing the cushion to the housing. The tether directly connects the cushion to the housing without requiring a separate retainer ring structure, thereby simplifying the device while maintaining securement reliability.
Solution Approach 2:
The tether serves multiple functions: it secures the cushion to the housing, provides lateral support, and enables deployment. By combining these functions into a single component rather than requiring separate retainer ring and support structures, the patent reduces device complexity while maintaining reliability.
2Reliability
If a larger retainer ring is used for passenger side airbag modules with elongated rectangular openings, then the cushion is securely mounted, but the manufacturing cost increases
Solution Approach 1:
The patent eliminates the need for large, custom-sized retainer rings for passenger side modules. The tether system can be used with standard-sized components regardless of the specific housing opening geometry, thereby reducing manufacturing costs while maintaining mounting security.
Solution Approach 2:
The patent changes the mounting approach from rigid retainer rings that must match specific opening dimensions to flexible tethers that can accommodate various housing geometries. This parameter change allows use of standardized, lower-cost components across different module types.
3Ease of manufacture
If the retainer ring size is reduced or securement location is moved to lower portion of housing, then manufacturing cost decreases, but lateral support for the cushion is compromised
Solution Approach 1:
The tether provides both securement and lateral support functions simultaneously. Even when positioned at lower portions of the housing or with reduced size, the tether maintains cushion stability through its tension-based support mechanism, unlike rigid retainer rings that require specific sizes and positions to provide lateral support.
Solution Approach 2:
The patent changes from rigid structural support via retainer rings to flexible tension-based support via tethers. This allows the securement system to maintain lateral support effectiveness regardless of size or position, enabling cost-reduced designs without compromising stability.
4Reliability
If traditional retainer ring methods are used, then the cushion is securely attached, but assembly time increases
Solution Approach 1:
The patent removes the multi-step retainer ring installation process and replaces it with direct tether attachment. This extraction of the complex retainer ring subsystem significantly reduces assembly time while maintaining attachment security through the simpler tether mechanism.
Solution Approach 2:
Instead of using a rigid retainer ring that requires precise installation into housing openings, the patent inverts the approach by using flexible tethers that can be attached to the cushion and then connected to housing mounting points. This reversal of the traditional mounting sequence simplifies the assembly process.
Data Source
AI summary
An inflatable cushion for an air bag module, the inflatable cushion comprising: an inflation opening for providing fluid communication to an interior of the inflatable cushion; a first tether having a cushion securement end and a mounting end, the cushion securement end being fixedly secured to the inflatable cushion and the mounting end having a mounting member, the mounting member being capable of pivotal movement with respect to the mounting end, wherein the mounting member is an integral portion of the first tether folded and secured upon itself to define the mounting member; and wherein the mounting member is capable of being positioned between a first position and a second position, the first position being orthogonal to a portion of the first tether and the second position being parallel to a portion of the first tether.