Laminated Airbag Web Lamination for Seam-Consistent Batch Production
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Solution Overview
Problem
Existing methods for producing laminated airbags, particularly those designed for rapid inflation and repeated deployment, face inefficiencies in seam integrity and manufacturing consistency due to separate lamination of individual airbag preforms, which can be time-consuming and introduce inconsistencies.
Innovation Solution
A method involving a flexible web of superimposed woven fabric layers with preformed airbag seams, followed by simultaneous cutting, lamination between thin film layers, and final separation to create laminated airbags, ensuring integral seams and efficient batch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate production of side airbags and curtain airbags is performed, then each airbag can be optimized for its specific function, but the number of production lines and inventory requirements increase
Solution Approach 1:
The patent combines side airbag and curtain airbag into a single laminated airbag structure that can be produced on one production line. The side airbag portion and curtain airbag portion are integrated in the laminated structure, allowing simultaneous production while maintaining functional optimization for both airbag types.
Solution Approach 2:
The laminated airbag is divided into distinct functional portions (side airbag portion and curtain airbag portion) with different material properties. The side airbag portion uses softer material for occupant protection, while the curtain airbag portion uses harder material for SRS function, achieving functional segmentation within a unified production system.
2Manufacturing precision
If separate production lines are used for side airbags and curtain airbags, then each airbag can be manufactured with appropriate material properties, but inventory requirements and production complexity increase
Solution Approach 1:
The patent uses composite material construction with at least two different materials having different hardness properties. The side airbag portion uses softer material for comfort and protection, while the curtain airbag portion uses harder material for structural integrity and SRS deployment, achieving precise material property control within a single laminated structure.
Solution Approach 2:
The single laminated airbag structure serves multiple functions by integrating both side airbag and curtain airbag portions. This multi-functional design allows one production line to manufacture airbags that can be deployed for different protection scenarios, reducing production line complexity while maintaining manufacturing precision.
3Productivity
If a single laminated airbag structure is used for both side and curtain airbag functions, then production efficiency increases, but the material selection becomes more complex
Solution Approach 1:
The patent applies local quality by assigning different material properties to different portions of the laminated airbag. The side airbag portion uses softer material optimized for occupant contact and protection, while the curtain airbag portion uses harder material optimized for SRS deployment characteristics, allowing efficient single-line production with targeted material selection.
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
Enhances seam integrity and manufacturing efficiency by maintaining structural integrity and reducing leakage, while allowing for rapid inflation and repeated deployments with consistent quality.
Implementation Method 1
a blowing agent which is in a solid state at standard temperature and pressure and has a melting point of -50°C or higher
Data Source
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AI summary
There is disclosed a method of producing laminated airbags. The method is specially configured to allow the batch lamination of a plurality of airbag preforms formed within an initial flexible web, and which remain connected to one another in web form throughout the lamination steps. The proposed method provides a much more convenient way of producing laminated airbags as it does not require the separate lamination of individual airbags.