3D Printed Integrated Gas Generator Filter Housing
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Solution Overview
Problem
Existing gas generators for vehicle occupant safety systems are complex and costly to manufacture due to the need for multiple components in the filter structure, which increases weight and size without improving gas generation efficiency.
Innovation Solution
A gas generator design where the filter structure is integrated into the outer housing as a single piece, produced using 3D printing, reducing the complexity of assembly and weight while enhancing heat exchange and filtration efficiency through labyrinthine channels and ribbed surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filter structure is manufactured from several components and assembled into the outer housing, then the filtration function is achieved, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The filter structure and outer housing are merged into a single integrated component manufactured as one piece using 3D printing technology. This eliminates the need for separate filter components and assembly steps, reducing manufacturing complexity while maintaining the filtration function through the integrated labyrinthine channel design
2Reliability
If the filter structure is manufactured from several components, then the filtration function is achieved, but the weight of the gas generator increases
Solution Approach 1:
The integration of filter structure and outer housing into a single component eliminates redundant materials and joining elements, reducing overall weight while maintaining filtration effectiveness through the optimized labyrinthine channel configuration
Solution Approach 2:
The 3D printing process enables localized optimization of material distribution within the integrated component, placing material only where structurally necessary while creating the filtration channels, thereby minimizing weight while maintaining both structural integrity and filtration function
3Reliability
If the filter structure is manufactured from several components, then the filtration function is achieved, but the size of the gas generator increases
Solution Approach 1:
The filter structure is integrated within the outer housing volume rather than being added as a separate component, utilizing the existing spatial envelope and reducing the overall gas generator size while maintaining the necessary filtration path length through labyrinthine channels
4Reliability
If multiple components are assembled to form the filter structure, then the filtration function is achieved, but the assembly time and production cost increase
Solution Approach 1:
The filter structure and outer housing are manufactured as a single integrated component using 3D printing, eliminating multiple assembly operations and reducing production time and labor costs while maintaining the filtration function through the integrated labyrinthine channel design
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 integrated design simplifies manufacturing, reduces weight and size, and improves gas filtration and cooling efficiency, ensuring reliable operation over time by preventing moisture and dirt ingress.
Implementation Method 1
at least one gas generator component, in particular an outer housing and/or an ignition unit of the gas generator, is produced using a 3D printing process, in particular a 3D screen printing process
Implementation Method 2
the filter structure has channels, in particular labyrinthine or meandering channels, which extend through the outer housing... there is an efficient heat exchange between the filter structure and the released gas, which is well cooled in this way
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The invention relates to a gas generator (10) for a vehicle occupant safety system, said generator comprising an outer housing (20) and a filter structure (30) for cleaning and/or cooling a gas released inside the outer housing (20), the filter structure (30) being integrated into the outer housing (20). The invention also relates to an airbag module and a vehicle occupant safety system comprising a gas generator of this type, in addition to a production method.