One-Piece Woven Airbag Structure for Shape-Controlled Inflation
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Solution Overview
Problem
The production of far-side airbags is complex, time-consuming, and costly due to the traditional cut, seal, and sew process, which results in bulky airbags that do not efficiently utilize limited installation space in vehicles, failing to meet the new Euro NCAP test requirements effectively.
Innovation Solution
A one-piece woven airbag with at least three fabric layers, where the warp and weft threads of the middle layer float between the lower and upper layers, allowing for simultaneous inflation of chambers and integration of X-tethers for controlled shape and stiffness, enabling a more efficient and cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the traditional cut, seal, and sew process is used to produce far-side airbags, then the airbags can achieve the required shape and stiffness for Euro NCAP compliance, but the production process becomes extremely complex, time-consuming, and costly
Solution Approach 1:
The patent combines multiple separate fabric pieces and assembly operations into a single integrated woven structure. The airbag is produced as one piece through a single weaving operation, merging what were previously separate components (multiple fabric pieces, sealing compounds, adhesive bonds, and sewn seams) into a unified structure that achieves the required shape and stiffness without complex assembly processes
Solution Approach 2:
The single woven structure performs multiple functions simultaneously: it provides the airbag chamber containment, creates the necessary shape through integrated stiffening chambers, forms sealing regions, and provides structural strength all through one weaving process, eliminating the need for separate components and assembly steps
2Strength
If multiple fabric pieces are sewn together with sealing compounds and adhesives to ensure protection, then the airbag achieves high stiffness and distinct shape, but the seams and layers make the airbag very bulky requiring more installation space
Solution Approach 1:
The patent uses a thin, single-layer woven fabric structure that maintains high stiffness through its编织 pattern and integrated chamber design rather than through multiple thick layers. The single woven structure acts as a flexible shell that provides the necessary structural integrity while minimizing bulk, allowing the airbag to achieve high strength without increased volume
3Manufacturing precision
If traditional multi-step assembly processes are used with multiple manual operations, then the airbag can be produced with required quality, but the production time and cost increase significantly
Solution Approach 1:
The patent performs all structural forming, chamber creation, and shape definition operations during the weaving process itself, before the airbag is removed from the loom. The stiffening chambers, sealing regions, and overall geometry are all predetermined and built into the fabric structure during manufacturing, eliminating the need for subsequent assembly operations and significantly improving production efficiency
Data Source
AI summary
The invention relates to an OPW (one piece woven) airbag comprising warp threads and weft threads which are woven into at least three woven fabric layers, a lower fabric layer (UG), an upper fabric layer (OG), and a central fabric layer (MG) arranged therebetween. The warp threads and weft threads of the central fabric layer (MG) protrude out of the central fabric layer (MG) and completely float between the lower fabric layer (UG) and the upper fabric layer (OG) in a first sub-region (ETB) of the OPW airbag and are integrated into the lower fabric layer (UG) or into the upper fabric layer (OG) in a second sub-region (ZTB) of the OPW airbag.