Sun Visor Airbag Layout for Reliable Windshield-Side Deployment

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Solution Overview

Problem

Airbag deployment in vehicle occupant restraint systems is hindered by the unpredictable position of vehicle occupants within the vehicle interior, requiring airbags to deploy effectively across various positions without interacting with sun visors or rigid roof lining components.

Innovation Solution

A vehicle occupant restraint system featuring an airbag module with a frontally acting airbag and inflator positioned between the sun visor pivot axis and windshield, allowing deployment without interaction with sun visors or rigid parts, utilizing a flexible wrapping and tether mechanism for precise positioning and minimizing the need for guiding plates or module casings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the airbag is positioned in the roof area between the sun visor pivot axis and windshield, then deployment without interaction with sun visor or rigid parts is achieved, but the space available for airbag module installation is limited

Engineering Contradiction:

Improvedeployment reliabilityVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The airbag module utilizes the transverse dimension (width) of the vehicle interior by positioning itself between the sun visor pivot axis and windshield, rather than occupying longitudinal space. This dimensional approach allows the module to deploy effectively while minimizing interference with other vehicle components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent applies local quality by positioning the airbag module in a specific localized area of the roof lining that is optimized for deployment. The module is placed in the region between the sun visor pivot axis and windshield, where the local geometric conditions favor reliable deployment without rigid component interference.

Inventive Principle:

Principle #3Local quality

2Reliability

If expensive module casings or guiding plates are used to define deployment passage, then deployment control is improved, but manufacturing cost increases

Engineering Contradiction:

Improvedeployment controlVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The airbag module utilizes the existing vehicle structure (roof lining, sun visor pivot axis, windshield) to define its deployment path. The system serves itself by using the vehicle's inherent geometric features as natural guides, eliminating the need for additional expensive guiding components or modular casings.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts and eliminates the expensive module casings and guiding plates from the system. By removing these unnecessary components, the design achieves deployment control through the vehicle's existing structure, thereby reducing manufacturing costs while maintaining reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Volume of stationary object

If the airbag module has larger transverse dimension to exploit limited space, then space utilization is improved, but the airbag may interfere with side components

Engineering Contradiction:

Improvespace utilizationVSAvoidside component interference

Core Design Contradiction:

Volume of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The airbag module is pre-positioned in the optimal location between the sun visor pivot axis and windshield during installation. This preliminary positioning ensures that when the airbag deploys, it充分利用 the available transverse space while naturally avoiding interference with side components due to the predetermined safe zone.

Inventive Principle:

Principle #10Preliminary action

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

Enables the airbag to deploy and position itself effectively across the windshield and instrument panel, absorbing occupants at various positions without rigid guiding components, thus enhancing protection and reducing the complexity and cost of the airbag module design.

Implementation Method 1

an inflator (18) which, upon activation, supplies filling gas for the airbag (16)

Methodology Applied

Scientific EffectGas expansion:

Data Source

PatentUS12077123B2Vehicle passenger restraint system comprising an airbag

Publication Date: 2024.09.03 DALPHI METAL ESPANA SA

AI summary

A vehicle occupant restraint system comprises an airbag module (12) which includes a frontally acting airbag (16) as well as an inflator (18) which upon activation supplies filling gas for the airbag (16), wherein prior to activation the airbag (16) is folded into an airbag package (14) and is disposed in the area of a sun visor (30) of a vehicle at a roof liner (23) of the vehicle. The airbag package (14) and the inflator (18) are substantially positioned, when viewed in the longitudinal vehicle direction (R), between a pivot axis (28) of the sun visor (30) and a windshield (26) of the vehicle.