Multiple-Component Plastic Generator Carrier for Vibration Damping

Solution Overview

Problem

Conventional gas bag modules face challenges in achieving optimal vibration damping and noise reduction while maintaining high stability, often requiring multiple metal sheets that increase complexity and tolerances, affecting both functionality and visual appearance.

Innovation Solution

A gas bag module with a generator carrier made from multiple-component plastic, combining a hard carrier component with an elastic coating for vibration damping and noise reduction, where the carrier forms the module housing and includes detent elements for secure attachment to the steering wheel, allowing for reduced component count and improved fit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If multiple metal sheets are used for vibration damping and noise reduction, then vibration damping and noise reduction are improved, but device complexity and manufacturing tolerances increase

Engineering Contradiction:

Improvevibration and noiseVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The generator carrier is made from multiple-component plastic consisting of a hard carrier component and an elastic coating component. This composite material structure provides both structural stability and vibration damping properties, replacing the need for multiple separate metal sheets while maintaining the desired noise and vibration reduction effects.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention combines the carrier structure and the vibration damping function into a single integrated generator carrier component. The elastic coating is applied directly onto the hard carrier component, merging what would traditionally be separate components (carrier + multiple metal sheets) into one unified structure, thereby reducing device complexity and cumulative tolerances.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If multiple metal sheets are used for vibration damping and noise reduction, then vibration damping and noise reduction are improved, but manufacturing precision and tolerances worsen

Engineering Contradiction:

Improvevibration and noiseVSAvoidcumulative tolerances

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The generator carrier is made from multiple-component plastic consisting of a hard carrier component and an elastic coating component. This composite material structure provides both structural stability and vibration damping properties, replacing the need for multiple separate metal sheets while maintaining the desired noise and vibration reduction effects.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention combines the carrier structure and the vibration damping function into a single integrated generator carrier component. The elastic coating is applied directly onto the hard carrier component, merging what would traditionally be separate components (carrier + multiple metal sheets) into one unified structure, thereby reducing device complexity and cumulative tolerances.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If a hard carrier material is used for stability, then structural stability is improved, but vibration damping and noise reduction worsen

Engineering Contradiction:

Improvestructural stabilityVSAvoidvibration and noise

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The generator carrier is made from multiple-component plastic consisting of a hard carrier component and an elastic coating component. This composite material structure provides both structural stability and vibration damping properties, replacing the need for multiple separate metal sheets while maintaining the desired noise and vibration reduction effects.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The generator carrier has different material properties at different locations/levels: the hard carrier component provides structural stability where needed, while the elastic coating layer provides vibration damping and noise reduction. This local differentiation of material quality allows simultaneous achievement of stability and vibration damping without compromising either property.

Inventive Principle:

Principle #3Local quality

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 solution effectively reduces noise and vibration, enhances stability, and minimizes tolerances, improving the overall performance and aesthetic integration of the gas bag module within the steering wheel.

Implementation Method 1

through the introduction of an elastic component, in addition to a hard carrier component, a vibration-damping or noise-reducing effect (the latter to avoid rattling noises) can be achieved

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS7540530B2Gas bag module and vehicle steering wheel comprising such gas bag module

Publication Date: 2009.06.02 ZF AUTOMOTIVE SAFETY GERMANY GMBH

AI summary

A gas bag module (10) comprises a gas generator (16) and a generator carrier (12), to which the gas generator (16) is fastened and via which the gas generator (16) can be fastened directly or indirectly to a vehicle steering wheel (100). The generator carrier (12) consists at least partially of a multiple-component plastic (30, 32). There is further proposed a vehicle steering wheel (100) including such gas bag module (10).