Variable-Basis-Weight Headliner Core for Side Air Bag Deployment
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Solution Overview
Problem
Existing composite materials used in automotive headliners lack the ability to ensure consistent air bag deployment while maintaining stiffness, as uniform basis weights do not allow for controlled failure at the edges during air bag deployment.
Innovation Solution
A method of producing a composite material with a variable basis weight across the core layer, where the central area has a higher basis weight than the edges, achieved by applying differential pressures during the formation process, allowing for controlled failure at the edges during air bag deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform basis weight is used throughout the core layer, then the headliner maintains consistent structural properties, but air bag deployment is compromised due to inability to control failure at edges
Solution Approach 1:
The core layer is designed with spatially varying basis weight: higher basis weight in the central area provides structural stability, while lower basis weight at the edges enables controlled failure during air bag deployment. This local differentiation resolves the contradiction by allowing the same component to have different properties in different regions.
Solution Approach 2:
The core layer is segmented into distinct zones (central area with higher basis weight and edge areas with lower basis weight) that serve different functional purposes. The central zone maintains structural integrity while the edge zones are designed to fail controllably, thus enabling reliable air bag deployment.
2Reliability
If the central area has higher basis weight than edges, then controlled failure at edges during air bag deployment is enabled, but manufacturing complexity increases due to differential pressure application
Solution Approach 1:
A differential pressure system is employed during the air-laying manufacturing process to achieve the desired basis weight distribution. By applying different pressures to different zones of the forming support element, the system controls material deposition to create higher basis weight in the central area and lower basis weight at the edges.
3Use of energy by moving object
If a lighter composite material design is used, then fuel efficiency is improved, but stiffness requirements for the headliner may not be met
Solution Approach 1:
The headliner uses local quality differentiation with higher basis weight in the central area to maintain necessary stiffness and structural support, while lower basis weight at the edges reduces overall weight. This strategic material distribution achieves the optimal balance between weight reduction for fuel efficiency and maintaining required stiffness.
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
This approach enhances air bag deployment efficiency while maintaining the necessary stiffness for the headliner, improving fuel efficiency and reducing vehicle weight by allowing for a lighter, more effective composite material design.
Implementation Method 1
a fibrous blanket made using an air-laying technique
Implementation Method 2
providing a negative pressure to less than an entire surface of the forming support element comprising the disposed foam
Implementation Method 3
a web of open celled structures formed by the reinforcing fibers held together by the thermoplastic material
Implementation Method 4
drying the porous web comprising the variable basis weight to provide a composite material
Data Source
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AI summary
Methods of producing core layers with a variable basis weight across a width of the core layer are described. The core layers can be used in vehicle headliners to permit proper side air bag deployment in the vehicles during crashes. Systems and various materials used to produce the core layers are also described.