Airbag design

The air bag system consists of three basic parts-an air bag module, crash sensors and a diagnostic unit. Some systems may also have an on/off switch, which allows the air bag to be deactivated.

The air bag module contains both an inflator unit and the lightweight fabric air bag. The driver air bag module is located in the steering wheel hub, and the passenger air bag module is located in the instrument panel. When fully inflated, the driver air bag is approximately the diameter of a large beach ball. The passenger air bag can be two to three times larger since the distance between the right-front passenger and the instrument panel is much greater than the distance between the driver and the steering wheel.

The crash sensors are located either in the front of the vehicle and/or in the passenger compartment. Vehicles can have one or more crash sensors. The sensors are typically activated by forces generated in significant frontal or near-frontal crashes. Sensors measure deceleration, which is the rate at which the vehicle slows down. Because of this, the vehicle speed at which the sensors activate the air bag varies with the nature of the crash. Air bags are not designed to activate during sudden braking or while driving on rough or uneven surfaces. In fact, the maximum deceleration generated in the severest braking is only a small fraction of that necessary to activate the air bag system.

The diagnostic unit monitors the readiness of the air bag system. The unit is activated when the vehicle's ignition is turned on. If the unit identifies a problem, a warning light alerts the driver to take the vehicle for examination of the air bag system. Most diagnostic units contain a device that stores enough electrical energy to deploy the air bag if the vehicle's battery is destroyed very early in a crash sequence.

Some vehicles without rear seats, such as pick-up trucks and convertibles, or with rear seats too small to accommodate rear-facing child safety seats, have manual ON/OFF switches for the passenger air bag installed at the factory. ON/OFF switches for driver or passenger air bags may also be installed by qualified service personnel at the request of owners who meet government-specified criteria and who receive government permission. An air bag off-switch may be used when an occupant is at risk, this includes: infants riding in rear-facing infant seats in the front passenger seat; children aged 1 to 12 in the front passenger seat; drivers who cannot keep 10 inches between the center of the steering wheel and the center of their breastbone; and people with particular medical conditions.

Initially, most vehicles featured a single airbag, mounted in the steering wheel and protecting the driver of the car (who is the most at risk of injury). During the 1990s, airbags for front seat passengers, then separate side impact airbags placed between the door and occupants, became common.



Triggering conditions

Air bags are typically designed to deploy in frontal and near-frontal collisions, which are comparable to hitting a solid barrier at approximately 8 to 14 miles per hour (mph) (13 to 23 km/h). Roughly speaking, a 14 mph (23 km/h) barrier collision is equivalent to striking a parked car of similar size across the full front of each vehicle at about 28 mph (45 km/h). This is because the parked car absorbs some of the energy of the crash, and is pushed by the striking vehicle. Unlike crash tests into barriers, real-world crashes typically occur at angles, 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 air bag in a real-world crash can be much higher than an equivalent barrier crash.

Because air bag sensors measure deceleration, vehicle speed and damage are not good indicators of whether an air bag should have deployed. Occasionally, air bags can deploy due to the vehicle's undercarriage violently striking a low object protruding above the roadway surface. Despite the lack of visible front-end damage, high deceleration forces may occur in this type of crash, resulting in the deployment of the air bag.

The airbag sensor is a MEMS accelerometer, which is a small integrated circuit chip with integrated micromechanical 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, which 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.

There was some work initially in mercury switches but they did not work very 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 very little friction or hysteresis. This device was developed at Sandia National Laboratories. The rolamite and similar macro-mechanical devices were used in air bags until the mid-1990s when they were universally replaced with MEMS.

Most air bags are designed to automatically deploy in the event of a vehicle fire when temperatures reach 300 to 400 degrees Fahrenheit (150 to 200 °C). This safety feature helps to ensure that such temperatures do not cause an explosion of the inflator unit within the air bag module.

Today, airbag triggering algorithms are becoming much more complex. They try to reduce useless 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 as very 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.



Deployment mechanism

When there is a moderate to severe frontal crash that requires the frontal air bag to deploy, a signal is sent to the inflator unit within the air bag module. An igniter starts a rapid chemical reaction generating primarily nitrogen gas (N2) to fill the air bag making it deploy through the module cover. Some air bag technologies use compressed nitrogen gas while other technologies use various energetic propellants. Propellants containing sodium azide (NaN3) were very common in early inflator designs. However, propellants containing sodium azide were widely phased out during the 1990s in pursuit of less expensive and less toxic alternatives.

From the onset of the crash, the entire deployment and inflation process is faster than the blink of an eye. Airbags deploy in 1/20 of 1 second. Because a vehicle changes speed so fast in a crash, air bags must inflate rapidly if they are to help reduce the risk of the occupant hitting the vehicle's interior.

Once an air bag deploys, deflation begins immediately as the gas escapes through vents in the fabric. Deployment is frequently accompanied by the release of dust-like particles in the vehicle's interior. Most of this dust consists of cornstarch or talcum powder, which are used to lubricate the air bag during deployment. In older designs, small amounts of sodium hydroxide may initially be present. 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). Depending on the type of air bag 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. With the onset of symptoms, asthmatics should treat themselves as advised by their doctor, then immediately seek medical treatment.

Some airbags in certain car models deploy twice, for two crashes; it first deploys and deflates and may re-inflate.

Air bags must inflate very rapidly to be effective, and therefore come out of the steering wheel hub or instrument panel with considerable force, generally at a speed of about 220 mph. Because of this initial force, contact with a deploying air bag may cause injury. These air bag contact injuries, when they occur, are typically very minor abrasions or burns. The sound of air bag deployment is very loud, in the range of 165 to 175 decibels for 0.1 second. Hearing damage can result in some cases.

More serious injuries are rare; however, serious or even fatal injuries can occur when someone is very close to, or in direct contact with an air bag module when the air bag deploys. Such injuries may be sustained by unconscious drivers who are slumped over the steering wheel, unrestrained or improperly restrained occupants who slide forward in the seat during pre-crash braking, and even properly restrained drivers who sit very close to the steering wheel. Objects must never be attached to an air bag module or placed loose on or near an air bag module, since they can be propelled with great force by a deploying air bag, potentially causing serious injuries.

An unrestrained or improperly restrained occupant can be seriously injured or killed by a deploying air bag. The National Highway Traffic Safety Administration (NHTSA) recommends drivers sit with at least 10 inches (254 mm) between the center of their breastbone and the center of the steering wheel. Children under 12 should always be properly restrained in a rear seat. A rear-facing infant restraint must never be put in the front seat of a vehicle with a front passenger air bag. A rear-facing infant restraint places an infant's head close to the air bag module, which can cause severe head injuries or death if the air bag deploys. Modern cars include a switch to turn off the airbag system of the passenger seat, in which case a child-supporting seat must be installed.



Advanced airbag design

Many advanced air bag technologies are being developed to tailor air bag 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 air bag module. Many of these systems will use multi-stage inflators that deploy less forcefully in stages in moderate crashes than in very severe crashes. Occupant sensing devices let the air bag diagnostic unit know if someone is occupying a seat in front of an air bag, whether the person is an adult or a child, whether a seat belt or child restraint is being used and whether the person is forward in the seat and close to the air bag module. Based on this information and crash severity information, the air bag is deployed at either a high force level, a less forceful level or not at all.

Many new vehicles are also equipped with side air bags. While there are several types of side air bags, all are designed to reduce the risk of injury in moderate to severe side impact crashes. These air bags are generally located in the outboard edge of the seat back, in the door or in the roof rail above the door.

The Citroën C4 provides the first "shaped" driver airbag - made possible by this car's innovative fixed hub steering wheel.

Seat and door-mounted air bags all provide upper body protection. Some also extend upwards to provide head protection. Two types of side air bags, known as inflatable tubular structures and inflatable curtains, are specifically designed to reduce the risk of head injury and/or help keep the head and upper body inside the vehicle. A few vehicles are now being equipped with a different type of inflatable curtain designed to help reduce injury and ejection from the vehicle in rollover crashes.



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.