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Recently, the automotive industry has become more interested in knee injury, particularly in the application and development of knee airbag modules in vehicles to achieve a good rating during EuroNCAP and IIHS tests. Also, EuroNCAP and IIHS press the automotive industry to equip vehicles with knee airbag modules for occupant safety improvement in barrier tests. (1) Therefore, an invisible knee airbag module has been independently developed through design, simulation, static deployment tests and dynamic knee impact tests. A knee airbag module development process has been established and test results that were obtained from the development process are presented. Also, some design considerations for invisible knee airbag module development are discussed in this paper. A knee airbag module, which has been changed to match the IP lower panel shape and packaging specific vehicle environment, will be developed and produced in the near future.

The integrated correlation methodology is applied to the correlation of the airbag body block test and the component tests of sub systems consisting of the steering control system. By using the optimization technique for the occupant simulation model involving two-dimensional curves as the input, the optimal scale factors of the input F-D curves are found in order to minimize the sum of deviations between simulation and test results. In addition, the optimal one-dimensional unknown inputs that can't be obtained by component tests are found. It is found that the optimization technique used in this study is very suitable for the correlation of the occupant simulation model that has 2-dimensional test input data, and it is able to shorten the entire correlation time and ensure the reliability of the correlation result. This correlation methodology can be applied to the sled test and the barrier test for validating the occupant analysis model.

TPO (thermoplastic olefin) composite for rear bumper back beams was developed. In this study, the composition of PP (polypropylene), rubber and mineral fillers was optimized to minimize the intrusion and the failure after crash. The optimization of the composition was achieved using the mixture design of experiments. The physical properties of TPO composites with various compositions were investigated and the effect of each material on the crash performance of back beam was studied through CAE (computer-aided engineering). The back beams made of the optimized TPO composite for a subcompact car were prepared for the ECE 42 crash test and the TPO-based back beam showed even better performance than conventional PC/PBT-based counterpart. In addition, the newly developed composite has delivered a 15 ~ 40% cost saving and 4 ~ 10% weight reduction versus conventional PC/PBT and GMT (glass mat-reinforced thermoplastic).

In current inflatable curtain airbag development process, the curtain airbag performance is developed sequentially for the airbag coverage, FMVSS 226, FMVSS 214 and NCAP. Because the FMVSS 226 for the ejection mitigation and the NCAP side impact test require the opposite characteristics in terms of the dynamic stiffness of the inflatable curtain airbag, the sequential development process cannot avoid the iteration for dynamic stiffness optimization. Airbag internal pressure characteristics are can be used to evaluate the airbag performance in early stage of the development process, but they cannot predict dynamic energy absorption capability. In order to meet the opposite requirements for both FMVSS 226 and NCAP side impact test, a test and CAE simulation method for the inflatable curtain airbag was developed.