Foldable Airbag Module Container Design
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Solution Overview
Problem
Existing airbag modules have complex and expensive manufacturing processes due to multi-part casings and covers, which complicate handling, installation, and increase costs.
Innovation Solution
A one-piece foldable airbag module container made from a flat sheet of plastic material with pre-cut lines, allowing for easy manufacturing and deployment, featuring flaps and closure means that can be weakened or reversible for efficient cushion deployment and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-part casings and covers are used in airbag modules, then protection and structural integrity are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple separate components (casings and covers) into a single integrated container structure. The container is formed from a single flat sheet of plastic material that is folded and sealed to create a complete housing, eliminating the need for separate casing parts and covers that would require multiple manufacturing steps and assembly operations.
Solution Approach 2:
The single container structure performs multiple functions simultaneously: it provides structural protection for the airbag module, serves as the housing for the gas generator and cushion, acts as the deployment chamber, and includes integrated sealing flaps. This multi-functional design replaces what would traditionally require several separate components.
2Reliability
If multi-part casings and covers are used in airbag modules, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate components (casings and covers) into a single integrated container structure. The container is formed from a single flat sheet of plastic material that is folded and sealed to create a complete housing, eliminating the need for separate casing parts and covers that would require multiple manufacturing steps and assembly operations.
Solution Approach 2:
The invention changes the manufacturing approach from traditional multi-part injection molding to a single-sheet forming process. By altering the manufacturing parameter from multiple molded parts to a single formed structure, the patent reduces tooling costs, material waste, and assembly operations while maintaining structural integrity.
3Ease of manufacture
If a one-piece foldable container is used, then manufacturing simplicity and cost reduction are achieved, but cushion deployment control must be ensured
Solution Approach 1:
The patent segments the container structure by introducing pre-cut lines and fold lines in the flat sheet. These segmentation features create defined folding zones and sealing flaps that control how the container deforms during deployment. The segmentation allows the container to fold in predictable ways while maintaining structural integrity during normal handling.
Solution Approach 2:
The container is designed to be dynamic rather than rigid - the pre-cut lines and fold flaps allow the structure to deform controllably during cushion deployment. The container transitions from a rigid protective housing to a flexible deployment structure that can open and expand to accommodate the deploying airbag cushion.
Data Source
Figure 1a~2
Figure 3a~3b
Figure 3c~5b
AI summary
The invention relates to an airbag module for automotive vehicles, comprising a gas generator (15) and an inflatable cushion (13) which are housed in a container (11) which is prismatic in shape and formed by folding a flat sheet of suitable material in which its large sides (31, 33), its back side (35) and, as extensions of the sides of said large sides (31), flaps (37, 37', 37") corresponding to the sides of the closing surface of the container (11), are defined by means of pre-cut lines, said flaps (37, 37', 37") and the large side (33) they are separated from including cooperating means (41, 43, 45) defined by means of pre-cut lines, which allow closing the container (11). The container (11) additionally includes means (51, 53) defined by means of pre-cut lines intended for aiding in positioning and fixing the airbag module in the vehicle.