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A research program was initiated to evaluate the performance of prototype dual stage passenger air bags in terms of both restraint system performance and deployment aggressivity for different size occupants. Variations in inflator partitions, vent hole diameter sizes, and deployment timing were examined. High speed unbelted sled tests were conducted with both 50th percentile male and 5th percentile female Hybrid III adult dummies at 48 kmph; and belted sled tests were conducted at 56 kmph. Low risk deployment tests with child dummies were conducted to evaluate air bag aggressivity. Overall, it was concluded that the dual stage air bag systems under evaluation had improved performance over the baseline single stage systems in terms of providing high speed protection while reducing aggressivity to out-of-position occupants; however, some dual stage systems may require additional occupant detection methodologies to suppress or control inflation.

In the United States, air bags will be required in all passenger cars and light trucks under Federal Motor Vehicle Safety Standard (FMVSS) No. 208, Occupant Crash Protection. Even after full implementation of driver and passenger air bags as required by FMVSS No. 208, frontal impacts will still account for up to 8,000 fatalities and 120,000 moderate to critical injuries (i.e., injuries of AIS ≥ 2) [1]. The National Highway Traffic Safety Administration (NHTSA) has an ongoing research program to address these fatalities and injuries and provide a basis for the possible future upgrade of FMVSS No. 208. This effort includes developing supplementary test procedures for the evaluation of occupant injury in higher severity crashes, developing improved injury criteria including criteria for assessing injuries to additional body regions, and evaluating the injuries associated with occupant size [2, 3 and 4].