Ford Unveils Ultra-Compact Knee Airbag System

Ford Motor Co. will debut a new knee airbag system for front-seat passengers in the 2015 Mustang sport coupe that is dramatically smaller, lighter and simpler than conventional systems.

The unit consists of a pliable, inflatable injection-molded plastic bladder that fits inside the glove box door. In a crash, the bladder inflates, pushing the entire glove box door toward the passenger's knees to cushion them against impact.

Ford says the design is about one-third the weight of a conventional knee airbag system. It uses an inflator that is only one-fourth the size. And because it inflates in a straight line toward the passenger's knees, it can operate at lower inflation pressures than conventional systems the inflate downward, then curve upward toward the passenger's legs, according to Ford.

The architecture eliminates seams or a conventional airbag cover. It also enables designers to move the instrument panel closer to the windshield, thus creating more roominess without compromising airbag performance.

Ford has collected 15 U.S. patents related to the new technology so far. The bladder is part of an enhanced safety system in the 2015 Mustang that doubles to eight the number of airbags, adds seatbelt pretensioners and uses more sensors to better assess the nature of an impact.

The company says it is mulling other locations and applications for the bladder system.