Single-Panel Knee Airbag with Internal Tethers and Pleats
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Solution Overview
Problem
Current inflatable knee airbag systems face challenges in achieving optimal deployment trajectories and shapes due to limitations in tether placement and reinforcement, which can result in suboptimal protection during collisions.
Innovation Solution
The design involves strategically placing first and second tethers within the inflatable airbag cushion, along with a pleat formation and reinforcement materials, to guide the airbag into a predetermined deployment trajectory and shape, enhancing protection by allowing precise control over inflation and deployment characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate components (tethers, reinforcements, panels) are used to control airbag deployment, then deployment precision can be improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate components (tethers, reinforcements, and panel sections) into a single integrated panel structure. The tether attachments, reinforcement zones, and panel geometry are all formed from one continuous piece of material, eliminating the need for separate components while maintaining precise deployment control through the integrated design of these elements.
Solution Approach 2:
The single panel is divided into distinct functional zones including tether attachment regions, reinforcement zones, and deployment control sections. This segmentation of functionality within a unified structure allows precise control over different aspects of deployment (trajectory, shape, force distribution) without requiring multiple separate physical components to be assembled.
2Strength
If traditional multi-panel construction is used, then structural strength can be achieved, but manufacturing time and complexity increase
Solution Approach 1:
The invention merges multiple panels into a single monolithic structure that is formed and deployed as one piece. This eliminates the need for assembling multiple panels together, significantly reducing manufacturing steps and time while maintaining structural integrity through the continuous material construction and integrated reinforcement zones.
3Manufacturing precision
If internal tethers are added to control deployment shape, then deployment precision improves, but manufacturing complexity increases
Solution Approach 1:
The tethers are integrated directly into the panel structure during manufacturing, with tether attachment points and tether bodies formed as part of the single panel. This eliminates the need for separate tether installation steps and reduces device complexity while maintaining precise deployment shape control through the strategically placed tether attachments within the unified structure.
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 ensures the airbag adopts a consistent shape during deployment, providing enhanced protection by optimizing the distribution of force and ensuring effective inflation, thereby improving occupant safety in collision scenarios.
Implementation Method 1
inflatable knee airbag cushion assemblies
Data Source
AI summary
An airbag assembly with a reduced-cost knee airbag cushion and internal tethers can be formed from a single rectangular panel of material so that there is very little material waste. A pleat can be formed in a rear face so that the combination of tethers and pleat help the cushion deploy with favorable characteristics and adopt an arced shape when inflated. The cushion can have apertures for inserting an inflator with mounting stems partially within the cushion so that the mounting stems can be used to couple the cushion to an airbag housing. The assembly can also have a bag strap formed from a single piece of fabric that can wrap around a rolled and/or folded cushion. The assembly can also have a stabilizer strap that can be coupled to the cushion and to the airbag housing so that during deployment, the cushion does not skew or twist.