Integrated Vehicle Safety Tensioner Design
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Solution Overview
Problem
Existing vehicle safety device tensioners require significant mounting effort and space due to multiple components, leading to increased costs and complexity.
Innovation Solution
A compact tensioner design where the tubular casing integrates a receiving area for the closure member and a fastening portion, allowing direct fastening to the vehicle frame with a single fastening means, and incorporating a closure member that serves as a cable guide and integral subassembly to reduce components and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (tubular casing, closure member, fastening portion, cable guide) are used in the tensioner, then each component can be optimized for its specific function, but the mounting effort and assembly complexity increase significantly
Solution Approach 1:
The patent combines the tubular casing, closure member, fastening portion, and cable guide into an integrated unit. The closure member is formed as a single piece that simultaneously serves as the fastening portion and includes the cable guide, eliminating the need for separate components and reducing assembly steps while maintaining functional optimization.
Solution Approach 2:
The closure member is designed to perform multiple functions simultaneously: it closes the tubular casing, serves as the fastening portion for mounting to the vehicle frame, and incorporates the cable guide for the tensioning cable. This multi-functionality reduces the total component count and assembly complexity.
2Ease of manufacture
If multiple separate components are used in the tensioner, then each component can be manufactured independently, but the mounting effort and space requirements increase
Solution Approach 1:
The closure member is formed as a single integrated component that combines the closing function, fastening function, and cable guiding function. This integration reduces the total volume and space required for the tensioner while still allowing for efficient manufacturing processes.
Solution Approach 2:
The multi-functional closure member performs multiple operations within a single component structure, reducing the overall space requirement for the tensioner assembly while maintaining the ability to manufacture the component efficiently using processes like injection molding.
3Reliability
If multiple separate components with numerous contact points are used, then functional requirements can be met, but careful seating and mounting expenditure increase considerably
Solution Approach 1:
The integration of the closure member as a single piece with built-in cable guide and fastening features eliminates numerous contact points between separate components. This reduces the need for careful seating and alignment during assembly, thereby reducing mounting expenditure while maintaining functional requirements.
4Reliability
If a traditional multi-component tensioner design is used, then each component can be optimized, but the tensioner requires increased space due to numerous components
Solution Approach 1:
The patent merges multiple components into a single integrated closure member that performs multiple functions. This integration significantly reduces the total volume of the tensioner by eliminating the space required for separate components and the gaps between them, while still maintaining optimized functional performance.
Solution Approach 2:
The multi-functional closure member consolidates multiple functions into one component, reducing the overall volume of the tensioner assembly. The integrated design eliminates redundant structures and spacing requirements, achieving compact dimensions while maintaining functional optimization.
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 design reduces mounting effort and space requirements while maintaining high quality, enabling efficient assembly and operation with reduced component count and improved cable guiding properties.
Implementation Method 1
an inflator is provided which in the case of release acts on the piston so that the piston is displaced in the tubular casing
Implementation Method 2
the closure member itself includes the cable guide for the tensioning cable defecting the tensioning cable in an arc shape
Data Source
AI summary
A tensioner (10) for a vehicle safety device is provided with a tubular casing (12) in which a piston (18) is movably supported as well as with a closure member (26) closing the tubular casing (12) on the front face and forming a cable guide (38) for a tensioning cable (28) which may be connected to a belt buckle or an end fitting (34) and in which cable guide the tensioning cable (28) is deflected in arc shape. Further, the tensioner (10) comprises an inflator (24) accommodated in the closure member (26), wherein the tubular casing (12) includes a receiving area (14) for receiving the closure member (26) as well as a fastening portion (16) serving for fastening the tensioner (10) to a vehicle frame.