Side-Mounted Disk Inflator Airbag Assembly for Narrow Module Width
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Solution Overview
Problem
Existing disk-type inflators in airbag modules face challenges in meeting space constraints due to their width, which is often greater than the preferred or required width of the module, and alternative inflators like tubular types are more expensive.
Innovation Solution
The use of disk-type inflators in a side-mounted configuration within the module, where the height extends along the width of the module, allowing for a narrower design without requiring new or more expensive inflators, and incorporating features like deflection tunnels and a deflection plate to redirect and cool inflation gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If disk-type inflators are used in conventional orientations, then inflation capability is maintained, but module width exceeds maximum specifications
Solution Approach 1:
The patent applies dimensional reorientation by mounting the disk-type inflator on its side rather than in the conventional upright position. This changes the spatial orientation from vertical to horizontal, allowing the inflator's height dimension to align with the module's width dimension, thereby reducing the module's width while maintaining inflation capability.
Solution Approach 2:
The patent introduces asymmetry in the mounting configuration by positioning the inflator at an angle (specifically 90 degrees from conventional orientation) relative to the module housing. This asymmetric mounting allows the inflator to fit within the constrained width while still delivering inflation gases effectively through redirected pathways.
2Length of stationary object
If tubular inflators are used to meet width specifications, then module width is reduced, but manufacturing cost increases
Solution Approach 1:
The patent uses an existing disk-type inflator design (a proven, cost-effective component) and replicates its functionality in a different orientation rather than developing a new tubular inflator design. This approach leverages existing manufacturing infrastructure and component availability, avoiding the increased costs associated with developing and producing new inflator types.
Solution Approach 2:
The patent changes the mounting parameters (orientation angle, position) of the existing disk-type inflator rather than changing the inflator type itself. This parameter adjustment allows the same cost-effective inflator to meet the width specifications that would otherwise require more expensive alternative inflators.
3Length of stationary object
If disk-type inflators are side-mounted, then module width is reduced, but inflation gas flow path becomes more complex
Solution Approach 1:
The patent introduces a diffuser element as an intermediary component that facilitates the transition of inflation gases from the horizontally oriented inflator to the vertically deployed airbag. This diffuser element simplifies the gas flow path by providing a dedicated interface that directs and distributes gases efficiently, reducing the complexity that would otherwise result from the unconventional mounting orientation.
Solution Approach 2:
The patent segments the gas flow path into distinct functional zones: the inflator chamber, the diffuser element interface, and the airbag deployment chamber. This segmentation allows each component to be optimized for its specific function, managing the complexity of the redirected gas flow through clear functional separation rather than a single complex pathway.
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 configuration maximizes space utilization, reduces the need for additional cushion materials and heat shielding components, and allows for narrower airbag assemblies while maintaining effective gas distribution and cooling.
Implementation Method 1
The inflator may then be configured to deliver inflation gases in a direction corresponding with, or parallel to, the width
Implementation Method 2
incorporating features like deflection tunnels and a deflection plate to redirect and cool inflation gases
Data Source
AI summary
Airbag cushions and related assemblies configured to accept side-mounting of airbag inflators and/or otherwise accommodate narrowing of an airbag module width. In some embodiments, the assembly may comprise an inflator housing defining a plenum. An airbag cushion may be fluidly coupled with the plenum and/or inflator housing and may define a throat region. A disk inflator may be coupled to the housing in a side-mounted configuration such that inflation gases from the disk inflator are configured to enter the plenum and then be directed into the airbag cushion via the throat region.