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When automated driving becomes a reality, drivers will be able to change their seating position during phases without driving responsibility. To protect them optimally in the event of a crash, even if they are in a more comfortable seating position, new airbag concepts are necessary that adapt their depth of effectiveness to the respective seating position. ZF Lifetec has already developed a so-called Dual-Contour Airbag for the passenger side, which can be inflated in two different sizes depending on the seating position, to the point of application readiness. Now, the company is also working on such a Dual-Contour Airbag for the driver's side for the next generation of partially or fully automated vehicles.
Enlarged Airbag
Crash tests have shown: If a frontal crash occurs while the front passengers are in the comfort seating position - a backrest inclination of about 40° - the classic combination of belt and airbag can no longer optimally protect the occupants. In this seat setting, the distance between the inflated airbag and the occupant is too great to optimally catch and restrain the passenger. It must be noted that for this inclination specification, the 90-degree angle from backrest to seat surface is defined as the 0-point. The normal seating position is thus at about 20°. With a view to automated driving, a solution is therefore necessary that offers high safety for both positions. This is the idea behind the Dual-Contour Airbag. In simple terms, the solution consists of an airbag that is standardly designed for the standard seating position, but can be correspondingly enlarged when the occupants are in a comfort seating position.
One Airbag, Two Sizes
In its development process, ZF Lifetec uses experience gained from the development of the dual-contour passenger airbag. The dual-contour driver airbag also offers two stages, which extend further depending on whether the person behind the wheel is in an upright or comfort seating position. The two-stage mechanism can be controlled via a control unit that switches a system of restraint bands. The restraint bands are connected to an active release unit that frees them as needed.
Gas Generator for Extra Volume
To fully deploy the dual-contour driver airbag, the gas fill volume must be increased. For this purpose, a two-stage gas generator is necessary, which ZF Lifetec has developed for airbags with particularly large volumes. It is capable of filling both volume sizes of the driver airbag integrated into the steering wheel within milliseconds. Development manager Harald Lutz emphasizes that this type of airbag on the driver's side can exhibit depth adaptability of approximately 200 mm. The maximum total fill volume of a dual-contour airbag is currently achieved on the passenger side and amounts to up to 190 liters, which according to ZF Lifetec is unique in the market.
Adjusted Fill Pressure
Since the airbag control is integrated into the car's electronics, the vehicle system "knows," for example, in which seating position the driver is at the moment of the crash and which stage of the gas generator needs to be activated. In addition to seat angle and weight sensors, other sensors such as interior cameras can be integrated into the system for a more accurate assessment of the interior scenario.
Therefore, it is possible to implement another adaptation in the dual-contour airbag: the fill pressure of the airbag can vary depending on the size, weight, and stature of the occupants. If sensors or interior cameras provide the corresponding information and, for instance, detect a large, heavy person behind the wheel, outflow openings can be actuated to create a higher fill pressure and thus higher occupant retention.
"With this adaptive system, which ZF Lifetec already offers in series applications for other airbags, the retention function of the airbag is already more efficient in many vehicles today and also aligns with the 'Real-Life Safety' approach," Lutz summarizes.
About ZF Lifetec
ZF Lifetec is a provider of passive safety systems for enhanced vehicle occupant protection. The company, with around 36,000 employees, develops and produces a product portfolio that includes airbags, seat belts, and steering wheels, covering a wide range of vehicle types - from small volume segment vehicles to sophisticated luxury cars. With a market share of over 20% in its core product categories, ZF Lifetec is present in 48 locations across 20 countries worldwide. In the 2023 fiscal year, the company generated a revenue of 4.6 billion euros.
Translated automatically from German.
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