Side Airbag Module with One-Piece Rear Cover Panel
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Solution Overview
Problem
Current side airbag systems require multiple components and complex designs, leading to increased manufacturing and labor costs, as well as time-consuming re-testing when seatback trim is adjusted, and often necessitate a guide member for proper airbag deployment.
Innovation Solution
A simplified side airbag system with a seatback frame, an airbag module, and a one-piece rear cover panel that allows the airbag to deploy forward without a guiding member, reducing components and deployment time, and utilizing foam cushion padding for support and deformation during deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a guide member is added to direct airbag deployment, then deployment accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the guide member from the airbag system entirely. The airbag module is positioned to deploy directly forward through the seatback trim without requiring any guiding components, thereby reducing device complexity and manufacturing cost while maintaining deployment accuracy through proper positioning of the inflator device and airbag module.
Solution Approach 2:
The patent segments the airbag deployment function into two independent elements: (1) the airbag module positioned to deploy forward, and (2) the seatback trim with predetermined tear lines that guide deployment. This eliminates the need for a separate guide member while maintaining controlled deployment direction.
2Reliability
If multiple components are used in the airbag system, then deployment control is improved, but manufacturing time and material costs increase
Solution Approach 1:
The patent merges the functions of multiple components into fewer elements. The seatback trim serves both as a structural component and as a deployment guide through its predetermined tear lines. The airbag module integrates the inflator device and airbag in a single assembly that deploys directly forward, eliminating the need for separate guide members and reducing manufacturing steps.
Solution Approach 2:
The seatback trim is designed with multi-functionality: it provides structural support, aesthetic coverage, and deployment guidance through predetermined tear lines. This universal design eliminates the need for dedicated guide members, reducing component count while maintaining reliable deployment control.
3Adaptability or versatility
If seatback trim is made adjustable, then adaptability is improved, but re-testing requirements and labor costs increase
Solution Approach 1:
The patent incorporates predetermined tear lines into the seatback trim during manufacturing. These pre-established features ensure that the airbag will deploy correctly regardless of trim adjustments, eliminating the need for re-testing when trim is modified. The tear lines are designed to fail at specific locations that maintain proper deployment geometry.
4Strength
If deployment pressure is increased to improve forward deployment, then airbag stiffness is improved, but inflator device complexity increases
Solution Approach 1:
The patent applies local quality by positioning the inflator device and airbag module to deploy directly forward into the foam cushion padding. This geometric arrangement allows the use of lower deployment pressures because the force is applied directly in the desired direction without requiring guide members to redirect the airbag, thereby maintaining airbag stiffness while reducing inflator complexity.
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 system achieves faster and more efficient airbag deployment with increased pressure and stiffness, reducing material and manufacturing costs while eliminating the need for a guide member and simplifying the deployment process.
Implementation Method 1
an inflator device, which is coupled to the seatback frame, and an airbag that is coupled to the inflator device. The inflator device is positioned for deploying the airbag substantially forward
Implementation Method 2
The seatback includes foam cushion padding, which is deformed by the airbag upon its deployment
Data Source
AI summary
A side airbag system (12) for a vehicle is provided. The side airbag system (12) includes a seatback frame (16) having a front side (20), a rear side (22), and an outboard side (24). The outboard side (24) of the seatback frame (16) has an airbag module (26) coupled thereto and extending substantially outboard from the seatback frame (16). The airbag module (26) is positioned for deploying an airbag (30) substantially forward. The rear side (22) of the seatback frame (10) has a rear cover panel (40) attached thereon. This rear cover panel (40) is a one-piece element for covering the airbag module (26) and both the rear side (22) and the outboard side (24) of the seatback frame (16). The system (12) also includes foam cushion padding (34), which is deformed by the airbag (30) upon its deployment.