Non-linear PSIR Door Scoring with Interlaced Interfaces

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Solution Overview

Problem

Conventional automotive PSIR door systems face issues with the bending strength of the common tear line, which can weaken due to manufacturing stresses, thermal effects, and passenger mistreatment, leading to potential fragmentation and reduced deployment performance.

Innovation Solution

A system and method for scoring an automotive milled PSIR door system with a substantially non-linear common tear line, formed by an interlaced interface between the PSIR doors, using a milling device to create a region of reduced thickness with straight linear ends, increasing bending strength while minimizing bridge pieces and maintaining tensile strength for airbag deployment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a straight common tear line is used in conventional PSIR door systems, then the deployment function is simple and effective, but the bending strength is insufficient leading to potential fragmentation and reduced aesthetics

Engineering Contradiction:

Improvebending strength of common tear lineVSAvoidcomplexity of tear line design

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies curvature by replacing the conventional straight common tear line with a substantially non-linear curved design. This curved configuration increases the bending strength of the tear line by distributing stresses more effectively along its length, preventing fragmentation while maintaining the required tensile strength for airbag deployment. The curved path allows the tear line to better accommodate thermal expansion, manufacturing stresses, and physical loads without compromising structural integrity or aesthetics.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If the common tear line is weakened to facilitate door opening, then the deployment performance is improved, but the resistance to manufacturing stresses and thermal effects is reduced

Engineering Contradiction:

Improvedeployment performanceVSAvoidsusceptibility to manufacturing stresses and thermal effects

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating a tear line with varying thickness along its length. The tear line features a reduced thickness region that provides the necessary weakness for reliable door opening during deployment, while the overall curved configuration and interlaced interface maintain sufficient strength to resist manufacturing stresses and thermal effects. This localized thinning allows the system to have both weak points for deployment and strong overall structure for durability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curved configuration of the tear line distributes thermal expansion and manufacturing stresses more evenly throughout the structure, reducing concentration of stresses at any single point. This curvature allows the tear line to accommodate dimensional changes and external loads while maintaining its integrity, thus improving resistance to harmful factors without compromising deployment reliability.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If the common tear line is made visible on the instrument panel surface, then the deployment can be observed, but the aesthetics are compromised

Engineering Contradiction:

Improvedeployment verificationVSAvoidaesthetics of instrument panel

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The substantially non-linear curved design of the common tear line, when combined with the interlaced interface configuration, allows the tear line to be positioned and shaped in a way that minimizes its visual impact on the instrument panel surface. The curved path can be routed to follow contours that are less noticeable, and the interlaced interface helps conceal the tear line within the door structure, maintaining aesthetics while still allowing deployment to occur.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 non-linear common tear line design enhances bending strength, resistance to manufacturing and environmental stresses, and reduces the risk of fragmentation, ensuring optimal airbag deployment and improved aesthetics by minimizing weakening and distortion.

Implementation Method 1

using a milling device to create a region of reduced thickness

Methodology Applied

Scientific EffectMilling:

Implementation Method 2

formed by an interlaced interface between the PSIR doors, increasing bending strength

Methodology Applied

Scientific EffectStress distribution:

Data Source

PatentUS7976057B2Automotive milled PSIR scoring with interlaced interfaces

Publication Date: 2011.07.12 INOAC USA INC

AI summary

An automotive Passenger Side Inflatable Restraint (PSIR) hidden door system contained in an automotive instrument panel and a method of scoring the PSIR door system. The system includes forward and rearward doors hingedly connected at first and second hinges, respectively, to a PSIR airbag chute. The system further includes a common tear line of reduced material thickness integrally joining the forward and rearward doors. The common tear line has a substantially non-linear shape with first and second linear ends.