Interlocking Air Bag Chute Flange Design
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Solution Overview
Problem
Existing air bag deployment systems face challenges in preventing foam leakage during the foam-in-place process and require additional components like fasteners for secure attachment of the air bag chute to the instrument panel substrate.
Innovation Solution
An air bag deployment chute with an encircling flange that interlocks with the instrument panel substrate using a series of tabs and notches, providing a seal and secure attachment without the need for fasteners, utilizing flexible gussets and tapered edges to ensure a compression seal and minimize foam leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam-in-place process is used to attach air bag chute to instrument panel substrate, then secure attachment is achieved, but foam leakage occurs during the process
Solution Approach 1:
A seal element is applied to the instrument panel substrate before the foam-in-place process to prevent foam leakage. The seal element is positioned in advance to block potential leakage paths between the air bag chute and the substrate, ensuring that foam remains contained during injection and curing.
Solution Approach 2:
A seal element acts as an intermediary component between the air bag chute and the instrument panel substrate. This intermediate layer prevents direct contact between foam and gaps in the assembly, blocking foam migration while still allowing the foam to provide secure attachment when properly contained.
2Reliability
If additional sealing components and fasteners are used to prevent foam leakage and secure attachment, then reliability is improved, but device complexity increases
Solution Approach 1:
The air bag chute assembly is integrated with the instrument panel substrate through a unified design where the seal element and mounting structure are combined into a single assembly. This integration eliminates the need for separate fasteners and sealing components, reducing part count while maintaining reliable attachment and preventing foam leakage.
Solution Approach 2:
The air bag chute assembly is designed to perform multiple functions simultaneously: it provides structural support, creates a seal to prevent foam leakage, and secures the air bag to the instrument panel. This multi-functionality eliminates the need for additional dedicated sealing components and fasteners, simplifying the overall device.
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 effectively prevents foam migration and ensures secure attachment of the air bag chute to the instrument panel substrate, eliminating the need for additional sealing components and fasteners, thereby enhancing the reliability and efficiency of the foam-in-place process.
Implementation Method 1
The flange has outer edges that are flexible and tapered to lie flat against the substrate surface to both seal the interface and minimize interference to the flow of foam during the foam-in-place injection process
Implementation Method 2
In cases where there is a foam-in-place process used to provide the foam layer between the air bag deployment door of a chute that is mounted on the instrument panel substrate and the outer skin layer
Data Source
AI summary
An integrated air bag chute structure that provides means for providing automatic interlocking attachment of the chute to the substrate of an instrument panel. By inserting the air bag chute into a substrate aperture and utilizing slots, depressions and notches formed in the chute structure beneath a surrounding flange, the aperture edges are captured and retained to thereby lock the chute in place.