Vehicle Trim Panel Airbag Deployment Notch Design
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Solution Overview
Problem
Existing vehicle interior trim components do not effectively facilitate airbag deployment with reduced break-through energy while maintaining a smooth visible surface, and current manufacturing processes are inefficient for producing such components.
Innovation Solution
A vehicle trim component with a panel comprising fibers, featuring a notch and protrusions or ribs formed through a combination of compression forming and injection molding, where the panel has varying thicknesses and densities to direct airbag deployment without visible protrusions on the surface, and resin is injected to form ribs on the backside for structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a notch is added to the trim component to facilitate airbag deployment, then airbag deployment effectiveness is improved, but the visible surface smoothness deteriorates
Solution Approach 1:
The patent applies local quality by creating a notch with varying thickness - the notch has reduced thickness at the deployment location to facilitate airbag breakthrough, while the visible surface maintains its original smooth appearance. The feature includes a first portion with first thickness and a second portion with second thickness less than the first thickness, allowing localized modification without affecting overall appearance.
2Use of energy by moving object
If the panel thickness is reduced at the notch location to facilitate airbag deployment, then break-through energy is reduced, but structural integrity deteriorates
Solution Approach 1:
The patent reduces panel thickness locally at the notch location (second thickness less than first thickness) to reduce break-through energy for airbag deployment, while maintaining adequate thickness in other areas to preserve overall structural integrity.
Solution Approach 2:
The patent uses a composite structure combining fiber panel material with resin material. The fiber panel provides structural framework while the resin portions (including the feature with varying thickness) provide localized modification for airbag deployment. This composite approach allows thickness reduction at specific locations without compromising overall strength.
3Manufacturing precision
If multiple manufacturing steps are used to create the notch and features, then manufacturing precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single compression molding process. The notch and associated features are formed simultaneously during the compression molding of the fiber panel, eliminating the need for separate post-processing steps to create the deployment notch and related features.
Solution Approach 2:
The patent performs preliminary action by pre-forming the notch and features during the initial compression molding process rather than adding them later. The mold cavity is designed with the notch geometry already incorporated, so the feature is created in advance during panel formation.
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 solution enables efficient airbag deployment with reduced break-through energy and maintains a smooth visible surface, while also improving structural integrity and reducing manufacturing complexity by using a single mold apparatus.
Implementation Method 1
compressing a first portion of the fiber panel between the first surface and a second surface of the mold to form the fiber panel into a compression formed component
Implementation Method 2
injecting resin into the mold to at least partially fill at least one void between the second surface of the mold and an uncompressed portion of the compression formed component to form a rib coupled to the compression formed component
Data Source
Figure 1A~1B
Figure 2A~2E
Figure 3A~3C
AI summary
A trim component for a vehicle interior is disclosed. The trim panel is prepared from a fiber panel. The trim component may be formed by concurrent compression forming and injection molding of the fiber panel within a single mold apparatus. Thermoplastic resin may be melted and injected to the back side of the fiber panel to improve structural rigidity and create greater strength difference between adjacent areas. The trim panel may provide at least one score line on the back side configured to direct airbag deployment. The score line may be compression formed onto the backside of the trim panel. The score line may reduce the strength of the area of the trim panel near the score line. Less energy may be required to break through the trim panel during air bag deployment. The trim panel may also provide a smooth visible surface.