The goals for the 1994 Acura Integra structure were to provide a strong, rigid platform to ensure a long, durable service life, create a stable base for the suspension, provide carefully designed front and rear crumple zones to minimize cabin intrusion in a collision, and ensure very tight tolerances to help provide the occupants with a quiet, vibration-free environment.
Another goal was to shift as much of the mass to the center of the vehicle as possible to enhance transient response and handling. Other considerations included the creation of a large greenhouse to maximize front and rear visibility, creating a large cabin that provides ample room while making the cabin intimate to enhance the feeling of a sports-oriented coupe and sedan.
The aerodynamic goal for the new Integra was to achieve a balance of forces that include moderate downforce at the rear, low turbulence, minimal wind roar in crucial areas such as the windows, excellent flow-through ventilation, and to provide optimum resistance to crosswinds while maintaining a low drag coefficient. This was achieved by extensive computer modeling, using the Cray supercomputer and wind-tunnel testing with scale models, mockups and prototype vehicle bodies. One important detail of the aerodynamic package is the one-piece, integral bumper assembly. This unit not only gives the Integra a cleaner, more modern appearance, but its flowing, one-piece construction eliminates gaps between the bumper and the body that tend to produce turbulence and disrupt laminar airflow over the hood. The Integra has a drag coefficient of 0.33 and a lift coefficient of 0.10.
To enhance corrosion protection, virtually every panel of the Integra is constructed of double-sided galvanized steel. The only significant panel that does not use galvanized steel is the roof. After assembly, the body in white is treated to an electro-deposition process that bonds a rust-inhibiting primer coating to the metal. Electro-deposition draws this coating into minute crevices, helping to ensure a barrier against rust-producing moisture. A moisture-resistant wax is also injected into hidden body cavities, to help prevent corrosion that might otherwise form from condensation.
Rigidity clearly has an impact on a number of critical areas. The suspension, for instance, no matter how finely calibrated or advanced in design, will not perform properly if the body flexes and bends under loading. Rigidity also contributes significantly to crash protection and reduction of vibration and exterior noise, and to the build quality perceived in areas like the small gaps between panels and openings.
Using the latest computer modeling and Finite Element Analysis techniques and using the 1993 Integra as a starting point, the engineering team set out to enhance the rigidity of the new Integra in every area. The 1994 Integra Sports Coupe is 40% stiffer in bending and 20% stiffer in torsional rigidity. The Sports Sedan is 50% stiffer in bending and 5% stiffer in torsional rigidity.
The use of a one-piece integral front bumper accomplishes a number of objectives. In addition to providing a cleaner, more modern and more aerodynamic appearance, it reduces the number of components and the weight of the front fascia, enhances the anti-corrosion performance of the entire front end, resists minor dents and flying debris better and, in case of a minor collision, helps reduce damage that might otherwise be transmitted to the front fenders.
The choice of using polypropylene for the front and rear bumper material was made based on its properties of resilience to minor damage and because at the end of the vehicle's service life, the bumper can be recycled. Due to the unique formulation of pigments and medium, the painted bumper resists the fading that was commonly associated with synthetic plastic bumpers. Like the bumpers on the 1993 Integra, the front and rear bumpers of the 1994 Integra resist damage up to a 5-mph collision.
One of the design priorities of the body was to provide the driver with as much visibility as possible. As a result of extensive engineering, which was able to create thin but strong pillars, and a compact engine, which contributes to a low cowl, the Sports Coupe offers 298.9 degrees of visibility while the Sports Sedan offers 306.3 degrees of visibility.
Pin-Guide Door Sash
The Integra Sports Coupe uses a pin-guide sash system for the door glass. A pin, which is bonded to the rear inside edge of the door glass, slides in a channel designed into the window sash. The pin holds the window captive against the sash and forms a tight seal to enhance the rigidity of the glass and resist the negative air pressure that builds up at the side of the vehicle at high road speeds. The system also allows tighter tolerances between the glass and the moulding, and contributes to better aerodynamics and reduced levels of wind noise.
In order to maximize head room, the Integra Coupe LS and GS-R and Sedan GS-R feature a moonroof that slides back and out of the roof proper. Unlike conventional sunroof configurations that slide into a receptacle in the roof, this unit takes up less head room.
Projector Beam Headlights
To enhance illumination and givethe Integra a more modern look, the engineers specified projector beam lamps for low-beam use. Compared to conventional units, these lamps reach 13 feet farther and illuminate an area 20% greater than those of the 1993 Integra. The high beams, which use improved halogen lamp technology, reach 125 feet farther and illuminate an area 2.5 times greater.
As mentioned earlier, the Integra provides a high degree of structural rigidity to enhance crash protection. At the front and rear, the Integra has been designed with deformable crumple zones. These are designed to deform in a controlled manner, absorb the impact energy and help prevent deformation of the passenger compartment.
Dual Air Bag Supplemental Restraint System (SRS)
The 1994 Integra is equipped with a driver's and front passenger's air bag Supplemental Restraint System (SRS). The driver's air bag is located in the steering wheel hub, while the passenger's air bag is located on top of the dash. Both air bags are triggered simultaneously by means of three impact sensors located in the passenger compartment. To ensure maximum reliability, the sensors use goldplated electrical connectors. As in all Acura automobiles, the front passenger's air bag is designed to deploy upward along the windshield and then back toward the occupant. This provides a large cushion to help protect the front passenger.
Three-Point Seat Belts
The dual front air bags are designed to work in conjunction with the 3-point seat belts. For easy access, the front buckles are attached to the driver's and front passenger's seats. The front seat belts on the Sports Sedan feature height adjusters on the B-pillars for comfort.
To help minimize injury to the occupant in a side-impact collision, the Integra features door intrusion beams as well as energy-absorbing pads in the doors.
On the Sports Sedan, there is a polypropylene pad located at hip level and a styrofoam pad located at shoulder level for both front and rear doors. The Sports Coupe, due to its different structural architecture, requires only a polypropylene pad. These pads substantially reduce the energy transmitted to the occupants in the event of an accident.