| Summary: |
An all plastic passenger airbag system with molded in
airbag chute, laser door pre-serration (cut) and insert molded polyester
hinge. Weight savings: ~ 1 Kg
due to metal replacement. Cost
savings: ~ $6 per instrument panel. |
| Most Innovative Feature: |
All plastic (metal free) passenger airbag system. Molded in
airbag chute, laser door pre-serration (cut) and insert molded polyester
hinge. |
| Other Innovative Features: |
Polyester mesh hinge;
airbag chute integrated in air duct
and vibration welded together with instrument panel upper pad. |
| What Forming Process? |
Injection Molding (Insert Molding). |
| First Time Process Used: |
Yes. |
| Previous Process: |
Replaces: punching of metal support, brackets, chute and
hinge attached with rivets. |
| Tooling Innovations: |
Tooling innovation with special injector pins that capture
hinge mesh, places in tool and restrains mesh hinge in position for
injection molding. |
| New Material Developments: |
No special material required. Molded with standard 480P16. |
| Weight Savings: |
Approximately 1
kilogram metal replacement. |
| Cost Savings: |
Approx $ 6 / instrument panel. |
| Cost Avoidance: |
Reduced assembly time, reduced tooling costs (two tools
hinge, chute vs. one), lower car weight, greater recycability and ELV separation. |
| Direct Consumer Benefit: |
Reduces possible noise caused by metal / plastic interface. |
| Translates to Other Vehicles?: |
Yes. |
| Safety Benefits: |
Airbag system deploys slightly faster than "metal
hinged" systems in this combination
with PU Spray skin, PUR foam and Dylark S/MA- lid (upper pad). |
| Environmental Benefits: |
All plastic system (no metal) permits use of existing S/MA
resin recovery processes for via
existing pre and post consumer recycling techniques. |
| Additional Comments: |
None. |
