Instrument Panel Airbag Cover with Laser-Scorable Tear Seam
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Solution Overview
Problem
Conventional instrument panels with separate airbag doors create an unappealing aesthetic in vehicles, as the outer periphery of the door is visible, and achieving consistent laser scoring for hidden tear seams is challenging due to inconsistent absorption of laser light by materials like olefin-based skins.
Innovation Solution
A panel design with a deployable cover featuring a tear seam defined by a plurality of holes in the outer layer, where a residual wall thickness is maintained between the holes and the show surface, utilizing filler materials that absorb laser light at specific wavelengths to create an invisible tear seam for airbag deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate door is used to cover the airbag module, then the airbag can deploy through the door, but the outer periphery of the door is visible creating an unpleasing appearance
Solution Approach 1:
The patent merges the door function with the instrument panel cover by forming an integral hidden door within the cover itself. The door is created as a recessed portion of the cover that can separate during airbag deployment, eliminating the need for a separate visible door assembly and achieving a seamless aesthetic appearance.
2Reliability
If a tear seam is created in the instrument panel for airbag deployment, then the airbag can deploy, but the tear seam is visible from the exterior show surface
Solution Approach 1:
The patent addresses the visibility issue by moving the tear seam to a different dimensional plane - specifically, the tear seam is positioned on the inner surface or edge portions of the instrument panel cover rather than on the exterior show surface. This dimensional relocation allows the tear seam to remain functional while being hidden from exterior view.
3Ease of manufacture
If a CO2 laser is used to score the tear seam, then the tear seam can be formed, but the score depth consistency is poor due to inconsistent laser light absorption by olefin-based skin
Solution Approach 1:
The patent addresses the inconsistent laser absorption by modifying material parameters - specifically by incorporating laser-absorbing fillers or pigments into the olefin-based skin material. This parameter change enables the material to consistently absorb laser energy at the desired wavelength, achieving uniform score depth and reliable tear seam formation.
4Ease of manufacture
If the laser power is increased to penetrate through all layers, then the tear seam can be formed, but visual readthrough of the seam becomes visible on the show surface
Solution Approach 1:
The patent applies local quality by differentiating the properties of different layers - the exterior show surface layer is designed to resist laser penetration and maintain aesthetic appearance, while interior layers are designed to be penetrated by the laser to form the functional tear seam. This localized differentiation allows the tear seam to be formed without creating visible readthrough on the show surface.
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
The solution ensures consistent and aesthetically pleasing airbag deployment with improved laser scorability, reducing visible read-through and enhancing the appearance of the instrument panel while maintaining adequate resistive force and deployment efficiency.
Implementation Method 1
the outer layer includes at least one filler material, that exhibits an absorbance of a wavenumber of a laser used to form the plurality of holes
Data Source
AI summary
A panel having a deployable cover for an airbag module is provided. The panel having: an outer layer having a show surface and an inner surface opposite the show surface; a tear seam formed in the outer layer, the tear seam defined by a plurality of holes formed in the outer layer extending from the inner surface towards the show surface, wherein a residual wall thickness of the outer layer is located between each of the plurality of holes and the show surface, wherein the outer layer includes at least one filler material, that exhibits an absorbance of a wavenumber of a laser used to form the plurality of holes.