Share on Facebook Share on Twitter Email
Answers.com

air bag

 
Dictionary: air bag

n.
  1. An automotive passive restraint consisting of a bag that is designed to inflate upon collision and prevent passengers from pitching forward.
  2. A large inflatable bag made of strong rubber, used by rescue workers to lift a vehicle or heavy machinery or debris that has fallen upon or otherwise trapped a victim.

Search unanswered questions...
Enter a question here...
Search: All sources Community Q&A Reference topics
How Products are Made: How is an air bag made?
Top

Background

An air bag is an inflatable cushion designed to protect automobile occupants from serious injury in the case of a collision. The air bag is part of an inflatable restraint system, also known as an air cushion restraint system (ACRS) or an air bag supplemental restraint system (SRS), because the air bag is designed to supplement the protection offered by seat belts. Seat belts are still needed to hold the occupant securely in place, especially in side impacts, rear impacts, and rollovers. Upon detecting a collision, air bags inflate instantly to cushion the exposed occupant with a big gas-filled pillow.

A typical air bag system consists of an air bag module (containing an inflator or gas generator and an air bag), crash sensors, a diagnostic monitoring unit, a steering wheel connecting coil, and an indicator lamp. These components are all interconnected by a wiring harness and powered by the vehicle's battery. Air bag systems hold a reserve charge after the ignition has been turned off or after the battery has been disconnected. Depending on the model, the backup power supply lasts between one second and ten minutes. Since components vital to the system's operation might sit dormant for years, the air bag circuitry performs an internal "self-test" during each startup, usually indicated by a light on the instrument panel that glows briefly at each startup.

The crash sensors are designed to prevent the air bag from inflating when the car goes over a bump or a pothole, or in the case of a minor collision. The inflator fits into a module consisting of a woven nylon bag and a break-away plastic horn pad cover. The module, in turn, fits into the steering wheel for driver's-side applications and above the glove compartment for front passenger applications.

In a frontal collision equivalent to hitting a solid barrier at nine miles per hour (14.48 kilometers per hour), the crash sensors located in the front of the car detect the sudden deceleration and send an electrical signal activating an initiator (sometimes called an igniter or squib). Like a light bulb, an initiator contains a thin wire that heats up and penetrates the propellant chamber. This causes the solid chemical propellant, principally sodium azide, sealed inside the inflator to undergo a rapid chemical reaction (commonly referred to as a pyrotechnic chain). This controlled reaction produces harmless nitrogen gas that fills the air bag. During deployment the expanding nitrogen gas undergoes a process that reduces the temperature and removes most of the combustion residue or ash.

The expanding nitrogen gas inflates the nylon bag in less than one-twentieth (1/20) of a second, splitting open its plastic module cover and inflating in front of the occupant. As the occupant contacts the bag, the nitrogen gas is vented through openings in the back of the bag. The bag is fully inflated for only one-tenth (1/10) of a second and is nearly deflated by three-tenths (3/10) of a second after impact. Talcum powder or corn starch is used to line the inside of the air bag and is released from the air bag as it is opened.

History

The air bag traces its origin to air-filled bladders outlined as early as 1941 and first patented in the 1950s. Early air bag systems were large and bulky, primarily using tanks of compressed or heated air, compressed nitrogen gas (N2), freon, or carbon dioxide (CO2). Some of the early systems created hazardous byproducts. One particular system used gun-powder to heat up freon gas, producing phosgene gas (COCl2)—an extremely poisonous gas.

One of the first patents for automobile air bags was awarded to industrial engineer John Hetrick on August 18, 1953. Conceived by Hetrick after a near accident in 1952, the design called for a tank of compressed air under the hood and inflatable bags on the steering wheel, in the middle of the dash-board, and in the glove compartment to protect front seat occupants, and on the back of the front seat to protect rear seat passengers. The force of a collision would propel a sliding weight forward to send air into the bags. Many other inventors and researchers followed suit, all exploring slightly different designs, so that the exact technical trail from the early designs to the present system is impossible to note with certainty.

In 1968, John Pietz, a chemist for Talley Defense Systems, pioneered a solid propellant using sodium azide (NaN3) and a metallic oxide. This was the first nitrogen-generating solid propellant, and it soon replaced the older, bulkier systems. Sodium azide in its solid state is toxic if ingested in large doses, but in automotive applications is carefully sealed inside a steel or aluminum container within the air bag system.

Since the 1960s, air bag-equipped cars in controlled tests and everyday use have demonstrated the effectiveness and reliability. The Insurance Institute For Highway Safety conducted a study of the federal government's Fatal Accident Reporting System using data from 1985 to 1991, and concluded that driver fatalities in frontal collisions were lowered by 28 percent in automobiles equipped with air bags. According to another study conducted in 1989 by General Motors, the combination of lap/shoulder safety belts and air bags in frontal collisions reduced driver fatalities by 46 percent and front passenger fatalities by 43 percent.

In response to consumers' increased safety concerns and insurance industry pressure, the federal government has forced automobile manufacturers to upgrade their safety features. First, Department of Transportation (DOT) regulations require all cars, beginning with model year 1990, sold in the United States to be equipped with a passive restraint system. (Passive restraint systems—requiring no activation by the occupant—involve the use of automatic seat belts and/or the use of air bags.) If car manufacturers choose an air bag, then regulations require only a driver' s-side system until model year 1994, when air bag-equipped cars must include passive protection on the passenger's side as well. A 1991 law requires driver and passenger air bags in all cars by the 1998 model year and in light trucks and vans by 1999.

Raw Materials

As stated above, an air bag system consists of an air bag module, crash sensors, a diagnostic monitoring unit, a steering wheel connecting coil, and an indicator lamp. Both this section and the next ("The Manufacturing Process") will focus on the air bag module itself.

An air bag module has three main parts: the air bag, the inflator, and the propellant. The air bag is sewn from a woven nylon fabric and can come in different shapes and sizes depending on specific vehicle requirements. The driver's-side air bag material is manufactured with a heat shield coating to protect the fabric from scorching, especially near the inflator assembly, during deployment. Talcum powder or corn starch is also used to coat the air bag; either substance prevents the fabric from sticking together and makes it easier to assemble. Newer silicone and urethane coated air bag materials require little or no heat shield coating, although talcum powder or corn starch will probably still be used as a processing aid.

The inflator canister or body is made from either stamped stainless steel or cast aluminum. Inside the inflator canister is a filter assembly consisting of a stainless steel wire mesh with ceramic material sandwiched in between. When the inflator is assembled, the filter assembly is surrounded by metal foil to maintain a seal that prevents propellant contamination.

The propellant, in the form of black pellets, is primarily sodium azide combined with an oxidizer and is typically located inside the inflator canister between the filter assembly and the initiator.

The Manufacturing
Process

Air bag production involves three different separate assemblies that combine to form the finished end product, the air bag module. The propellant must be manufactured, the inflator components must be assembled, and the air bag must be cut and sewn. Some manufacturers buy already-made components, such as air bags or initiators, and then just assemble the complete air bag module. The following description of the manufacturing process is for driver-side air bag module assembly. Passenger-side air bag module assemblies are produced slightly differently.

Propellant

  • The propellant consists of sodium azide mixed together with an oxidizer, a substance that helps the sodium azide to burn when ignited. The sodium azide is received from outside vendors and inspected to make sure it conforms to requirements. After inspection it is placed in a safe storage place until needed. At the same time, the oxidizer is received from outside vendors, inspected, and stored. Different manufacturers use different oxidizers.
  • From storage, the sodium azide and the oxidizer are then carefully blended under sophisticated computerized process control. Because of the possibility of explosions, the powder processing takes place in isolated bunkers. In the event safety sensors detect a spark, high speed deluge systems will douse whole rooms with water. Production occurs in several redundant smaller facilities so that if an accident does occur, production will not be shut down, only decreased.
  • After blending, the propellant mixture is sent to storage. Presses are then used to compress the propellant mixture into disk or pellet form.

Inflator assembly

  • The inflator components, such as the metal canister, the filter assembly—stainless steel wire mesh with ceramic material inside—and initiator (or igniter) are received from outside vendors and inspected. The components are then assembled on a highly automated production line.
  • The inflator sub-assembly is combined with the propellant and an initiator to form the inflator assembly. Laser welding (using CO2 gas) is used to join stainless steel inflator sub-assemblies, while friction inertial welding is used to join aluminum inflator sub-assemblies. Laser welding entails using laser beams to weld the assemblies together, while friction inertial welding involves rubbing two metals together until the surfaces become hot enough to join together.
  • The inflator assembly is then tested and sent to storage until needed.

Air bag

  • The woven nylon air bag fabric is received from outside vendors and inspected for any material defects. The air bag fabric is then die cut to the proper shapes and sewn, internally and externally, to properly join the two sides. After the air bag is sewn, it is inflated and checked for any seam imperfections.

Final assembly of air bag module

  • The air bag assembly is then mounted to the tested inflator assembly. Next, the air bag is folded, and the breakaway plastic horn pad cover is installed. Finally, the completed module assembly is inspected and tested.
  • The module assemblies are packaged in boxes for shipment and then sent to customers.

Other components

  • The remaining components of the air bag system—the crash sensors, the diagnostic monitoring unit, the steering wheel connecting coil, and the indicator lamp—are combined with the air bag module during vehicle assembly. All the components are connected and communicate through a wiring harness.

Quality Control

The quality control aspect of air bag production is, obviously, very important because many lives depend on the safety feature. Two major areas where quality control is critical are the pyrotechnic or propellant tests and the air bag and inflator static and dynamic tests.

Propellants, before being inserted into inflators, are first subjected to ballistic tests to predict their behavior. A representative sample of inflators are pulled from the production line and tested for proper operation by a full-scale inflator test, which measures pressure—created by the generated gas inside a large tank 15.84 or 79.20 gallons (60 or 300 liters)—versus time in milliseconds. This gives an indication of the inflator system's ability to produce an amount of gas at a given rate, ensuring proper air bag inflation. The air bags themselves are inspected for fabric and seam imperfections and then tested for leaks.

Automated inspections are made at every stage of the production process line to identify mistakes. One air bag manufacturer uses radiography (x-rays) to compare the completed inflator against a master configuration stored in the computer. Any inflator without the proper configuration is rejected.

The Future

The future for air bags looks extremely promising because there are many different applications possible, ranging from aircraft seating to motorcycle helmets. The air bags of the future will be more economical to produce and lighter in weight; will involve smaller, more integrated systems; and will use improved sensors.

Side-impact air bags are another possibility that would work similar to driver- and passenger-side air bags. Side-impact air bags will most likely be mounted in the car door panels and deployed towards the window during impact to protect the head. Foam padding around the door structure would also be used to cushion the upper body in a side impact. Head and/or knee bolsters (energy absorbing pads) to complement the air bag system are also being investigated. Rear-seat air bags are also being tested but consumer demand is not expected to be high.

Aftermarket air bag systems—generic systems that can be installed on any vehicle already built—are not currently available. Since the effectiveness of an air bag depends on its sensors recognizing if a crash is severe enough to trigger deployment, a system must be precisely tuned to the way a specific car model behaves in a crash. Still, companies are exploring the future possibility of producing a modified air bag system for retrofit.

A hybrid inflator is currently being tested that uses a combination of pressurized inert gas (argon) and heat from a propellant to significantly expand the gas's volume. These systems would have a cost advantage, since less propellant could be used. Air bag manufacturers are also developing systems that would eliminate the sodium azide propellant, which is toxic in its undeployed form. Work is also underway to improve the coatings that preserve the air bag and facilitate its opening. Eventually the bags may not need coatings at all.

In the future, more sophisticated sensors called "smart" sensors will be used to tailor the deployment of the air bag to certain conditions. These sensors could be used to sense the size and weight of the occupant, whether the occupant is present (especially in the case of passenger-side air bags where deployment may be unnecessary if there are no passengers), and the proximity of the driver to the steering wheel (a driver slumped over the steering wheel could be seriously injured by an air bag deployment).

Where To Learn More

Periodicals

Chaikin, Don. "How It Works—Airbags," Popular Mechanics. June, 1991, p. 81.

Frantom, Richard L. "Buckling Down on Passenger Safety," Design News. October 2, 1989, pp. 116-118.

Gottschalk, Mark A. "Micromachined Airbag Sensor Tests Itself," Design News. October 5, 1992, p. 26.

Grable, Ron. "Airbags: In Your Face, By Design," Motor Trend. January, 1992, pp. 90-91.

Haayen, Richard J. "The Airtight Case for Air Bags," Saturday Evening Post. November, 1986.

Reed, Donald. "Father of the Air Bag," Automotive Engineering. February, 1991, p. 67.

Sherman, Don. "It's in the Bag," Popular Science. October, 1992, pp. 58-63.

Spencer, Peter L. "The Trouble with Air Bags," Consumers' Research. January, 1991, pp. 10-13.

[Article by: Glenn G. Whiteside]


Wikipedia: Airbag
Top
The driver and passenger front airbags, after having been deployed, in a Peugeot 306 car.

An airbag is a vehicle safety device. It is an occupant restraint consisting of a flexible envelope designed to inflate rapidly in an automobile collision, to prevent vehicle occupants from striking interior objects such as the steering wheel or window.

Contents

Terminology

Because no action by the vehicle occupant is required to activate or use the airbag, it is considered a passive safety device. This is in contrast to seat belts, which are considered active safety devices because the vehicle occupant must act to enable them.[1][2][3][4][5] Terminological confusion can arise from the fact that passive safety devices and systems — those requiring no input or action by the vehicle occupant — can themselves operate in an active manner; an airbag is one such device. Vehicle safety professionals are generally careful in their use of language to avoid this sort of confusion, though advertising principles sometimes prevent such syntactic caution in the consumer marketing of safety features.

Various manufacturers have over time used different terms for airbags. General Motors' first bags, in the 1970s, were marketed as the Air Cushion Restraint System. Common terms in North America include Supplemental Restraint System (SRS) and Supplemental Inflatable Restraint (SIR); these terms reflect the airbag system's nominal role as a supplement to active restraints, i.e., seat belts.

History

1975 Buick Electra with ACRS
In 1994, Ford of Europe made airbags standard equipment in all the cars they built

Invention

An American inventor, John W. Hetrick, a retired industrial engineer, designed the original safety cushion for automotive use in 1952 at his kitchen table. His patent lasted only 17 years - long before mainstream automotive usage. Dr. David S. Breed, invented and developed a key component for automotive use: the ball-in-tube inertial sensor for crash detection. Breed Corporation then marketed this innovation first in 1967 to Chrysler. A similar "Auto-Ceptor" crash-restraint, developed by Eaton, Yale & Towne Inc. for Ford was soon offered as an automatic safety system in the USA,[6] while the Italian Eaton-Livia company offered a variant with localized air cushions.[7]

As an alternative to seatbelts

Airbags for passenger cars were introduced in the United States in the mid-1970s, when seat belt usage rates in the country were quite low. Airbags were marketed as a convenient alternative to seat belts, while offering similar levels of protection to unbelted occupants in a head-on collision.[citation needed]

Ford built an experimental fleet of cars with airbags in 1971, followed by General Motors in 1973 on Chevrolet vehicles. The early fleet of experimental GM vehicles equipped with airbags experienced seven fatalities, one of which was later suspected to have been caused by the airbag.[8]

In 1974, GM made the ACRS or "Air Cushion Restraint System" available as a regular production option (RPO code AR3) in some full-size Buick, Cadillac and Oldsmobile models. The GM cars from the 1970s equipped with ACRS have a driver side airbag, a driver side knee restraint (which consists of a padded lower dashboard) and a passenger side airbag. The passenger side airbag, protects both front passengers and unlike most newer ones, it integrates a knee cushion, a torso cushion and it also has dual stage deployment which varies depending on the force of the impact. The cars equipped with ACRS have lap belts for all seating positions but they do not have shoulder belts. These were already mandatory equipment in the United Stated on closed cars without airbags for the driver and outer front passenger seating positions.

The development of airbags coincided with an international interest in automobile safety legislation. Some safety experts advocated a performance-based occupant protection standard rather than a standard mandating a particular technical solution, which could rapidly become outdated and might not be a cost-effective approach. As countries successively mandated seat belt restraints, there was less emphasis placed on other designs for several decades.[7]

Manufacturers emphasise that an airbag is not, and can not be an alternative to seatbelts. They emphasise that they are only supplemental to a seatbelt. Hence the commonly used term "Supplemental Restraint System" or SRS. It is vitally important that drivers and passengers are aware of this. In the majority of cases of death caused by air bags, seat belts were not worn.[citation needed]

As a supplemental restraint

Frontal airbag

The auto industry and research and regulatory communities have moved away from their initial view of the airbag as a seat belt replacement, and the bags are now nominally designated as Supplemental Restraint System (SRS) or Supplemental Inflatable Restraints.

In 1980, Mercedes-Benz introduced the airbag in Germany. as an option on its high-end S-Class (W126). In the Mercedes system, the sensors would tighten the seat belts, and then deploy the airbag on impact. This integrated the seat belts and airbag into a restraint system, rather than the airbag being considered an alternative to the seat belt.

In 1987, the Porsche 944 turbo became the first car in the world to have driver and passenger airbags as standard equipment. The Porsche 944 and 944S had this as an available option. The same year also saw the first airbag in a Japanese car, the Honda Legend[9].

Airbags became common in the 1980s, with Chrysler and Ford introducing them in the mid-1980s; it was Chrysler that made them standard equipment across its entire line in 1990 (except for trucks until 1995).[citation needed]

Audi was relatively late to offer airbag systems on a broader scale; until the 1994 model year, for example, the 80/90, by far Audi's 'bread-and-butter' model, as well as the 100/200, did not have airbags in their standard versions. Instead, the German automaker until then relied solely on its proprietary procon-ten restraint system.

In Europe, airbags were almost entirely absent from family cars until the early 1990s, except for Saab, who made them standard on the 900 Turbo in 1989 and on all models in 1990. The first European Ford to feature an airbag was the facelifted Escort MK5b in 1992; within a year, the entire Ford range had at least one airbag as standard. By the mid 1990s, European market leaders such as Vauxhall/Opel, Rover, Peugeot, Renault and Fiat had included airbags as at least optional equipment across their model ranges. By the end of the decade, it was very rare to find a mass market car without an airbag, and some late 1990s products, such as the Volkswagen Golf Mk4 also featured side airbags. The Peugeot 306 was a classical example of how commonplace airbags became on mass market cars during the 1990s. On its launch in early 1993 most of the range did not even have driver airbags as an option. By 1999 however, side airbags were available on several variants.

During the 2000s side airbags were commonplace on even budget cars, such as the smaller-engined versions of the Ford Fiesta and Peugeot 206, and curtain airbags were also becoming regular features on mass market cars. The Toyota Avensis, launched in 1998, was the first mass market car to be sold in Europe with a total of nine airbags. Although in some countries, such as Russia, airbags are still not standard equipment on all cars, such as those from Lada.

Variable force deployment front airbags were developed to help minimize injury from the airbag itself.

Shaped airbags

The Citroën C4 provides the first "shaped" driver airbag, made possible by this car's unusual fixed hub steering wheel.[10]

Side airbag

Side airbag inflated permanently for display purposes
A deployed curtain airbag in a Ford Mondeo

There are essentially two types of side airbags commonly used today, the side torso airbag and the side curtain airbag.

Side torso airbag

Side-impact airbags or side torso airbags are a category of airbag usually located in the seat, and inflate between the seat occupant and the door. These airbags are designed to reduce the risk of injury to the pelvic and lower abdomen regions. Some vehicles are now being equipped with different types of designs, to help reduce injury and ejection from the vehicle in rollover crashes.

The Swedish company Autoliv AB, was granted a patent on side airbags, and they were first offered as an option in 1994 on the 1995 model year Volvo 850, and as standard equipment on all Volvo cars made after 1995.

Side tubular or curtain airbag

In late 1997 the 1998 model year BMW 7-series and E39 5-series were fitted with a tubular shaped head side airbags, the "Head Protection System (HPS)" as standard equipment. This is an industry's first in offering head protection in side impact collisions.[11] This airbag also maintained inflation for up to seven seconds for rollover protection. However, this tubular shaped airbag design has been quickly replaced by an inflatable 'curtain' airbag for superior protection.

In May 1998 Toyota began offering the first side curtain airbag deploying from the roof on the Progrés.[12] In 1998 the Volvo S80 was first given curtain airbags to protect both front and rear passengers. They were then made standard equipment on all new Volvo cars from 1998 and while initially seat-mounted later versions deployed from the roof.

Roll-sensing side curtain airbags found on vehicles more prone to rollovers such as SUV's and pickups will deploy when a rollover is detected instead of just when an actual collision takes place. Oftentimes there is a switch to disable the feature in case the driver wants to take the vehicle offroad.

Curtain airbags have been said to reduce brain injury or fatalities by up to 45% in a side impact with an SUV. These airbags come in various forms (e.g., tubular, curtain, door-mounted) depending on the needs of the application.[13] Many recent SUVs and MPVs have a long inflatable curtain airbag that protects all 3 rows of seats.

Knee airbag

The automotive industry's first passenger side knee airbag (not separate) was already used on the 1970s General Motors cars, it was integrated in the passenger airbag that had a knee cushion and a torso cushion.[citation needed] The first driver's side and separate knee airbag was used in the 1996 model Kia Sportage vehicle and has been standard equipment since then. The airbag is located beneath the steering.[14] The Toyota Avensis became the first vehicle sold in Europe equipped with a driver’s knee airbag.[15][16] The EuroNCAP reported on the 2003 Avensis, "There has been much effort to protect the driver’s knees and legs and a knee airbag worked well."[17] Since then certain models have also included front passenger knee airbags.

Rear curtain airbag

In 2008, the Toyota iQ launched featuring the first production rear curtain shield airbag to protect the rear occupants heads in the event of a rear end impact.[18]

Rear center airbag

In 2009, Toyota developed the first production rear-seat center airbag designed to reduce the severity of secondary injuries to rear passengers in a side collision. This system deploys from the rear center console first appearing in on the redesigned Crown Majesta.[19]

Seat belt airbag

In 2009, the S-class ESF safety concept car showcased seatbelt airbags. They will be included standard on the production Lexus LFA in late 2010, and the 2011 Ford Explorer will offer rear seatbelt airbags as an option.

On motorcycles

Various types of airbags were tested on motorcycles by the UK Transport Research Laboratory in the mid 1970s. In 2006 Honda introduced the first production motorcycle airbag safety system on its Gold Wing motorcycle. Honda claims that sensors in the front forks can detect a severe frontal collision and decide when to deploy the airbag, absorbing some of the forward energy of the rider and reducing the velocity at which the rider may be thrown from the motorcycle.[20]

Airbag suits have also been developed for use by Motorcycle Grand Prix riders. They are connected to the motorcycle by a cable and deploy when the cable becomes detached from its mounting clip, inflating to protect the back.[21]

How airbags work

An ACU from a Geo Storm.

The design is conceptually simple; a central "Airbag control unit"[22] (ACU) (a specific type of ECU) monitors a number of related sensors within the vehicle, including accelerometers, impact sensors, side (door) pressure sensors[23], wheel speed sensors, gyroscopes, brake pressure sensors, and seat occupancy sensors. When the requisite 'threshold' has been reached or exceeded, the airbag control unit will trigger the ignition of a gas generator propellant to rapidly inflate a nylon fabric bag. As the vehicle occupant collides with and squeezes the bag, the gas escapes in a controlled manner through small vent holes. The airbag's volume and the size of the vents in the bag are tailored to each vehicle type, to spread out the deceleration of (and thus force experienced by) the occupant over time and over the occupant's body, compared to a seat belt alone.

The signals from the various sensors are fed into the Airbag control unit, which determines from them the angle of impact, the severity, or force of the crash, along with other variables. Depending on the result of these calculations, the ACU may also deploy various additional restraint devices, such as seat belt pre-tensioners, and/or airbags (including frontal bags for driver and front passenger, along with seat-mounted side bags, and "curtain" airbags which cover the side glass). Each restraint device is typically activated with one or more pyrotechnic devices, commonly called an initiator or electric match. The electric match, which consists of an electrical conductor wrapped in a combustible material, activates with a current pulse between 1 to 3 amperes in less than 2 milliseconds. When the conductor becomes hot enough, it ignites the combustible material, which initiates the gas generator. In a seat belt pre-tensioner, this hot gas is used to drive a piston that pulls the slack out of the seat belt. In an airbag, the initiator is used to ignite solid propellant inside the airbag inflator. The burning propellant generates inert gas which rapidly inflates the airbag in approximately 20 to 30 milliseconds. An airbag must inflate quickly in order to be fully inflated by the time the forward-traveling occupant reaches its outer surface. Typically, the decision to deploy an airbag in a frontal crash is made within 15 to 30 milliseconds after the onset of the crash, and both the driver and passenger airbags are fully inflated within approximately 60-80 milliseconds after the first moment of vehicle contact. If an airbag deploys too late or too slowly, the risk of occupant injury from contact with the inflating airbag may increase. Since more distance typically exists between the passenger and the instrument panel, the passenger airbag is larger and requires more gas to fill it.

Front airbags normally do not protect the occupants during side, rear, or rollover accidents.[24] Since airbags deploy only once and deflate quickly after the initial impact, they will not be beneficial during a subsequent collision. Safety belts help reduce the risk of injury in many types of crashes. They help to properly position occupants to maximize the airbag's benefits and they help restrain occupants during the initial and any following collisions.

In vehicles equipped with a rollover sensing system, accelerometers and gyroscopes are used to sense the onset of a rollover event. If a rollover event is determined to be imminent, side-curtain airbags are deployed to help protect the occupant from contact with the side of the vehicle interior, and also to help prevent occupant ejection as the vehicle rolls over.

Triggering conditions

Airbags are designed to deploy in frontal and near-frontal collisions more severe than a threshold defined by the regulations governing vehicle construction in whatever particular market the vehicle is intended for. U.S. regulations require deployment in crashes at least equivalent in deceleration to a 23 km/h(14 mph) barrier collision, or similarly, striking a parked car of similar size across the full front of each vehicle at about twice the speed. International regulations are performance based, rather than technology-based, so airbag deployment threshold is a function of overall vehicle design.

Unlike crash tests into barriers, real-world crashes typically occur at angles other than directly into the front of the vehicle, and the crash forces usually are not evenly distributed across the front of the vehicle. Consequently, the relative speed between a striking and struck vehicle required to deploy the airbag in a real-world crash can be much higher than an equivalent barrier crash. Because airbag sensors measure deceleration, vehicle speed and damage are not good indicators of whether an airbag should have deployed. Airbags can deploy due to the vehicle's undercarriage striking a low object protruding above the roadway due to the resulting deceleration.

The airbag sensor is a MEMS accelerometer, which is a small integrated circuit with integrated micro mechanical elements. The microscopic mechanical element moves in response to rapid deceleration, and this motion causes a change in capacitance, which is detected by the electronics on the chip that then sends a signal to fire the airbag. The most common MEMS accelerometer in use is the ADXL-50 by Analog Devices, but there are other MEMS manufacturers as well.

Initial attempts using mercury switches did not work well. Before MEMS, the primary system used to deploy airbags was called a "rolamite". A rolamite is a mechanical device, consisting of a roller suspended within a tensioned band. As a result of the particular geometry and material properties used, the roller is free to translate with little friction or hysteresis. This device was developed at Sandia National Laboratories. The rolamite, and similar macro-mechanical devices were used in airbags until the mid-1990s when they were universally replaced with MEMS.

Nearly all airbags are designed to automatically deploy in the event of a vehicle fire when temperatures reach 150-200 °C (300-400 °F).[25] This safety feature, often termed auto-ignition, helps to ensure that such temperatures do not cause an explosion of the entire airbag module.

Today, airbag triggering algorithms are becoming much more complex. They try to reduce unnecessary deployments (for example, at low speed, no shocks should trigger the airbag, to help reduce damage to the car interior in conditions where the seat belt would be an adequate safety device), and to adapt the deployment speed to the crash conditions. The algorithms are considered valuable intellectual property. Experimental algorithms may take into account such factors as the weight of the occupant, the seat location, seatbelt use, and even attempt to determine if a baby seat is present.

Inflation

When the frontal airbags are to deploy, a signal is sent to the inflator unit within the airbag control unit. An igniter starts a rapid chemical reaction generating primarily nitrogen gas (N2) to fill the airbag making it deploy through the module cover. Some airbag technologies use compressed nitrogen or argon gas with a pyrotechnic operated valve ("hybrid gas generator"), while other technologies use various energetic propellants. Propellants containing the highly toxic sodium azide (NaN3) were common in early inflator designs. However, propellants containing sodium azide were widely phased out during the 1990s in pursuit of more efficient, less expensive and less toxic alternatives.[citation needed]

The azide-containing pyrotechnic gas generators contain a substantial amount of the propellant. The driver-side airbag would contain a canister containing about 50 grams of sodium azide. The passenger side container holds about 200 grams of sodium azide.[26] The incomplete combustion of the charge due to rapid cooling leads to production of carbon monoxide (CO) and nitrogen(II) oxide as reaction by-products.[27]

The alternative propellants may incorporate, for example, a combination of nitroguanidine, phase-stabilized ammonium nitrate (NH4NO3) or other nonmetallic oxidizer, and a nitrogen-rich fuel different than azide (eg. tetrazoles, triazoles, and their salts). The burn rate modifiers in the mixture may be an alkaline metal nitrate (NO3-) or nitrite (NO2-), dicyanamide or its salts, sodium borohydride (NaBH4), etc. The coolants and slag formers may be eg. clay, silica, alumina, glass, etc.[28] Other alternatives are eg. nitrocellulose based propellants (which have high gas yield but bad storage stability, and their oxygen balance requires secondary oxidation of the reaction products to avoid buildup of carbon monoxide), or high-oxygen nitrogen-free organic compounds with inorganic oxidizers (e.g., di or tricarboxylic acids with chlorates (ClO3-) or perchlorates (HClO4) and eventually metallic oxides; the nitrogen-free formulation avoids formation of toxic nitrogen oxides).

From the onset of the crash, the entire deployment and inflation process is about 0.04 seconds — faster than the blink of an eye (about 0.2 seconds). Because vehicles change speed so quickly in a crash, airbags must inflate rapidly to reduce the risk of the occupant hitting the vehicle's interior.

Variable-force deployment

Advanced airbag technologies are being developed to tailor airbag deployment to the severity of the crash, the size and posture of the vehicle occupant, belt usage, and how close that person is to the actual airbag. Many of these systems use multi-stage inflators that deploy less forcefully in stages in moderate crashes than in very severe crashes. Occupant sensing devices let the airbag control unit know if someone is occupying a seat adjacent to an airbag, the mass/weight of the person, whether a seat belt or child restraint is being used, and whether the person is forward in the seat and close to the airbag. Based on this information and crash severity information, the airbag is deployed at either a high force level, a less forceful level, or not at all.

Adaptive airbag systems may utilize multi-stage airbags to adjust the pressure within the airbag. The greater the pressure within the airbag, the more force the airbag will exert on the occupants as they come in contact with it. These adjustments allow the system to deploy the airbag with a moderate force for most collisions; reserving the maximum force airbag only for the severest of collisions. Additional sensors to determine the location, weight or relative size of the occupants may also be used. Information regarding the occupants and the severity of the crash are used by the airbag control unit, to determine whether airbags should be suppressed or deployed, and if so, at various output levels.

Post-deployment view of a SEAT Ibiza airbag

Post-deployment

Once an airbag deploys, deflation begins immediately as the gas escapes through vent(s) in the fabric (or, as it's sometimes called, the cushion) and cools. Deployment is frequently accompanied by the release of dust-like particles, and gases in the vehicle's interior (called effluent). Most of this dust consists of cornstarch, french chalk, or talcum powder, which are used to lubricate the airbag during deployment. Newer designs produce effluent primarily consisting of harmless talcum powder/cornstarch and nitrogen gas. In older designs using an azide-based propellant (usually NaN3), varying amounts of sodium hydroxide nearly always are initially present. In small amounts this chemical can cause minor irritation to the eyes and/or open wounds; however, with exposure to air, it quickly turns into sodium bicarbonate (baking soda). However, this transformation is not 100% complete, and invariably leaves residual amounts of hydroxide ion from NaOH. Depending on the type of airbag system, potassium chloride (a table salt substitute) may also be present.

For most people, the only effect the dust may produce is some minor irritation of the throat and eyes. Generally, minor irritations only occur when the occupant remains in the vehicle for many minutes with the windows closed and no ventilation. However, some people with asthma may develop an asthmatic attack from inhaling the dust.

Regulatory specifications

United States

On 11 July 1984, the U.S. government amended Federal Motor Vehicle Safety Standard 208 (FMVSS 208) to require cars produced after 1 April 1989 to be equipped with a passive restraint for the driver. An airbag or an automatic seat belt would meet the requirements of the standard. Airbag introduction was stimulated by the U.S. National Highway Traffic Safety Administration.[29] However, airbags were not mandatory on light trucks until 1995.[citation needed]

In 1998, FMVSS 208 was amended to require dual front airbags, and de-powered, or second-generation airbags were also mandated. This was due to the injuries caused by first-generation airbags, though FMVSS 208 continues to require that bags be engineered and calibrated to be able to "save" the life of an unbelted 50th-percentile size and weight "male" crash test dummy.

Outside the U.S.A.

Most countries[who?] outside North America adhere to internationalized European ECE vehicle and equipment regulations rather than the U.S. Federal Motor Vehicle Safety Standards. ECE airbags are generally smaller and inflate less forcefully than U.S. airbags, because the ECE specifications are based around belted crash test dummies. In the United Kingdom, and most other developed countries there is no direct legal requirement for new cars to feature airbags. Instead, the Euro NCAP vehicle safety rating encourages manufacturers to take a comprehensive approach to occupant safety; a good rating can only be achieved by combining airbags with other safety features.[30] Thus almost all new cars now come with at least two airbags as standard.

Maintenance

Inadvertent airbag deployment while the vehicle is being serviced can result in severe injury, and an improperly installed or defective airbag unit may not operate or perform as intended. Some countries impose restrictions on the sale, transport, handling, and service of airbags and system components. In Germany, airbags are regulated as harmful explosives; only mechanics with special training are allowed to service airbag systems. Under German Federal Law, used but intact airbags are to be detonated under secure conditions, must not be passed on to third parties in any way, and no untrained person is permitted to handle airbags. Purchase is restricted to buying a new replacement unit for immediate installation by the seller's qualified personnel.[citation needed]

Some automakers (such as Mercedes-Benz) call for the replacement of undeployed airbags after a certain period of time to ensure their reliability in an accident. One example is the 1992 S500 which has an expiry date sticker attached to the door pillar.

Injuries and fatalities

Airbags can injure or kill vehicle occupants. To provide crash protection for occupants not wearing seat belts, U.S. airbag designs trigger much more forcefully than airbags designed to the international ECE standards used in most other countries. Recent airbag controllers can recognize if a belt is used, and alter the bag deployment parameters accordingly.[31]

Injuries such as abrasion of the skin, hearing damage from the extremely loud 165-175 dB deployment explosion, head injuries, eye damage, and broken nose, fingers, hands or arms can occur as the airbag deploys.[citation needed] Most vehicle airbags are inflated using hot gas generated by a chemical process. Using hot gas allows the required pressure to be obtained with a smaller mass of gas than would be the case using lower temperatures. However, the hot gas can pose a risk of thermal burns if it comes in contact with the skin during deployment and occupant interaction. Burns are most common to the arms, face and chest. These burns are often deep dermal or second-degree burns that take longer to heal and risk scarring.[citation needed]

In 1990, the first automotive fatality attributed to an airbag was reported,[32] with deaths peaking in 1997 at 53 in the United States.[citation needed] TRW produced the first gas-inflated airbag in 1994, with sensors and low-inflation-force bags becoming common soon afterwards. Dual-depth (also known as dual-stage) airbags appeared on passenger cars in 1998. By 2005, deaths related to airbags had declined, with no adult deaths and two child deaths attributed to airbags that year. Injuries remain fairly common in accidents with an airbag deployment.

Serious injuries are less common, but severe or fatal injuries can occur to vehicle occupants very near an airbag or in direct contact when it deploys. Such injuries may be sustained by unconscious drivers slumped over the steering wheel, unrestrained or improperly restrained occupants who slide forward in the seat during pre-crash braking, and properly belted drivers sitting very close to the steering wheel.

The increasing use of airbags may actually make rescue work for firefighters, emergency medical service and police officers more dangerous,[citation needed] because of the risk of deployment while the emergency responder is assisting or extracting vehicle occupants.

Improvements in sensing and gas generator technology have allowed the development of third generation airbag systems that can adjust their deployment parameters to size, weight, position and restraint status of the occupant. These improvements have demonstrated a reduced injury risk factor for small adults and children who had an increased risk of injury with first generation airbag systems.[33]

Air bag fatality statistics

From 1990 to 2008, the U.S. National Highway Traffic Safety Administration identified 175 fatalities caused by air bags. Most of these (104) have been children, while the rest are adults. About 3.3 million air bag deployments have occurred and the agency estimates more than 6,377 lives saved and countless injuries prevented.[32]

A rear-facing infant restraint put in the front seat of a vehicle places an infant's head close to the airbag, which can cause severe head injuries, or death if the airbag deploys. Some modern cars include a switch to disable the front passenger airbag (although not in Australia, where rear-facing child seats are prohibited in the front where an airbag is fitted), in case a child-supporting seat is used there.

In vehicles with side airbags, it is dangerous for occupants to lean against the windows, doors, and pillars, or to place objects between themselves and the side of the vehicle. Articles hung from a vehicle's clothes hanger hooks can be hazardous if the vehicle's side curtain airbags deploy.[34]

Aerospace and military applications

NASA engineers test the Mars Pathfinder airbag landing system on simulated Martian terrain

The aerospace industry and the US Government have applied airbag technologies for many years. NASA, and US DoD have incorporated airbag systems in various aircraft and spacecraft applications as early as the 1960s.

OH-58D CABS test

Airbag landing systems

The first use of airbags for landing were Luna 9 and Luna 13, which landed on the Moon in 1966 and returned panoramic images. The Mars Pathfinder lander employed an innovative airbag landing system, supplemented with aerobraking, parachute, and solid rocket landing thrusters. This prototype successfully tested the concept, and the two Mars Exploration Rover Mission landers employed similar landing systems. The Beagle 2 Mars lander also tried to use airbags for landing, but the landing was unsuccessful for reasons which are not entirely known.

Occupant protection

The US Army has incorporated airbags in its UH-60A/L[35][36] Black Hawk and OH-58D Kiowa Warrior[37] helicopter fleets. The Cockpit Air Bag System (CABS)[38] consists of forward and lateral airbags with an Electronic Crash Sensor Unit (ECSU). The CABS system was conceived and developed by the US Army Aviation Applied Technology Directorate, Fort Eustis, Va.[39] It is the first conventional airbag system for occupant injury prevention designed and developed specifically for helicopter applications.[40][41]

See also

References

  1. ^ Bags, Buckles, and Belts: The Debate over Mandatory Passive Restraints in Automobiles
  2. ^ U.S. air bag history
  3. ^ U.S. patent 6272412 - Passive restraint control system for vehicles
  4. ^ Passive Seatbelt Systems and the 65 MPH Speed Limit: A Cause for Concern
  5. ^ New York State memo re insurance discounts for passive restraints
  6. ^ Popular Science May, 1968
  7. ^ a b Safety Design, John Fenton, The Times January 24 1969
  8. ^ GM's ACRS
  9. ^ http://www.jsae.or.jp/autotech/data_e/7-3e.html
  10. ^ Wilson, Robert (3 August 2005). "Citroen C4". The Australian. http://www.theaustralian.news.com.au/story/0,20867,16128857-13232,00.html. Retrieved 3 November 2009. 
  11. ^ BMW Head Protection System Sets New Standard in Side-Impact Protection in Latest IIHS Crash Test
  12. ^ http://www.theautochannel.com/news/2007/07/23/055878.html
  13. ^ NHTSA Side-Impact Airbags
  14. ^ http://cms.firehouse.com/web/online/University-of-Extrication/Kia-Motors-Knee-Airbag-System/19$708
  15. ^ http://www.toyota.eu/06_Safety/04_implementing_passive_safety/02_airbags.aspx
  16. ^ http://www.toyoda-gosei.com/news/2003/030630.html
  17. ^ http://www.euroncap.com/tests/toyota_avensis_2003/172.aspx
  18. ^ http://www.autobloggreen.com/2008/09/30/toyota-develops-rear-curtain-airbag-for-tiny-iq/
  19. ^ http://blogs.edmunds.com/straightline/2009/03/toyota-unveils-first-rear-seat-center-airbag.html
  20. ^ Motorcycle News '06 Wing gets airbag 2 September 2005
  21. ^ Motorcycle News Dainese airbag suit in action 21 November 2007
  22. ^ Airbag control unit at Audi.com Glossary
  23. ^ Media Center at Continental.com
  24. ^ Safercar.gov
  25. ^ http://www.nhtsa.dot.gov/people/injury/airbags/airbags03/page3.html
  26. ^ ET 08/00: Sodium azide in car airbags poses a growing environmental hazard
  27. ^ Air bag inflator - US Patent 5806888
  28. ^ Thermally stable nonazide automotive airbag propellants - Patent 6306232
  29. ^ http://www-nrd.nhtsa.dot.gov/pdf/nrd-01/Esv/esv16/98S8P12.PDF
  30. ^ Frontal impact test description Euro NCAP website
  31. ^ NHTSA 49 CFR Parts 552, 571, 585, and 595, Docket Notice
  32. ^ a b National Highway Traffic Safety Administration Air Bag Fatalities
  33. ^ American Journal of Epidemiology, Association of First- and Second-Generation Airbags with Front Occupant Death in Car Crashes: A Matched Cohort Study, October 4, 2005.
  34. ^ Toyota Aurion: User Manual 2006 model - Australia
  35. ^ Defenselink article
  36. ^ US Army Demonstrates Simula's Cockpit Air Bag System at Helios.com
  37. ^ FAS OH-58D article
  38. ^ Simula CABS brochure
  39. ^ Air Defense concept papers
  40. ^ BNET News Release on AHS Annual Forum award
  41. ^ Simula Receives Orders for its Cockpit Air Bag Systems at All Business.com

External links


Essential Desk Reference: Automobile Safety: Air Bags
Top

Air bags reduce the risk of dying in a direct frontal crash by about 30 percent. Almost all adults are safer riding or driving with an airbag than without one. However, airbags can be a source of injury for children and some adults.

The main source of risk is proximity. For maximum safety, a driver’s chest should be at least 10 inches from the center of the steering wheel, and a passenger’s chest should be at least 10 inches from the dashboard. These margins can almost always be achieved by moving the seats and/or tilting their backs. Seatbelts should be worn, and should fit snugly. Children 12 and under should always ride in the back seat. Under no circumstances should you ever place a rear-facing child safety seat in front of an air bag.

If you are unable to seat yourself as recommended, or you have been advised by a doctor that you are at special risk from an air bag, you may apply to the National Highway Traffic Safety Administration (NHTSA) for an air bag on-off switch. You may also apply for a switch if you must accommodate a child 12 or under in your front seat.

Image U.S. National Highway Traffic Safety Administration (NHTSA). “Air Bag On-Off Switches: Questions and Answers,” www.nhtsa.dot.gov/people/injury/airbags/



Best of the Web: air bag
Top

Some good "air bag" pages on the web:


How?
auto.howstuffworks.com
 
 
 

 

Copyrights:

Dictionary. The American Heritage® Dictionary of the English Language, Fourth Edition Copyright © 2007, 2000 by Houghton Mifflin Company. Updated in 2009. Published by Houghton Mifflin Company. All rights reserved.  Read more
How Products are Made. How Products are Made. Copyright © 2002 by The Gale Group, Inc. All rights reserved.  Read more
Wikipedia. This article is licensed under the Creative Commons Attribution/Share-Alike License. It uses material from the Wikipedia article "Airbag" Read more
Essential Desk Reference. The Essenial Desk Reference Dictionary. Copyright © 2002 by Oxford University Press, Inc.. All rights reserved.  Read more