CN105270312B - 机动车辆的具有一体式安全气囊门的内部板及其制造方法 - Google Patents

机动车辆的具有一体式安全气囊门的内部板及其制造方法 Download PDF

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CN105270312B
CN105270312B CN201510123632.1A CN201510123632A CN105270312B CN 105270312 B CN105270312 B CN 105270312B CN 201510123632 A CN201510123632 A CN 201510123632A CN 105270312 B CN105270312 B CN 105270312B
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K.W.亨特
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Faurecia Interior Systems Inc
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    • B60—VEHICLES IN GENERAL
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Abstract

本发明涉及机动车辆的具有一体式安全气囊门的内部板及其制造方法。本文提供了用于机动车辆的具有一体式安全气囊门的内部板以及制造这类内部板的方法。在一个例子中，制造内部板的方法包括如下步骤：将安全气囊滑槽门组件的周边凸缘的一个或多个第一焊接特征焊接到基板上，以将周边凸缘附接到基板。所述一个或多个第一焊接特征是沿第一方向延伸的细长特征。将周边凸缘部段支架的一个或多个第一焊接特征焊接到基板上，以将安全气囊滑槽门组件附接到基板。一个或多个第二焊接特征是沿大致横向于第一方向的第二方向延伸的细长特征。

Description

机动车辆的具有一体式安全气囊门的内部板及其制造方法
技术领域
本发明总体涉及被构造用于机动车辆的可充气约束系统的内部板，更具体地，涉及用于机动车辆的具有一体式安全气囊门的内部板以及制造这类内部板的方法。
背景技术
机动车辆通常包括可充气约束设备，其具有位于车辆内部板（诸如仪表板、门板等）之中或之后的可展开安全气囊。许多内部板包括形成到内部板中的一体式展开门，其被设计为在安全气囊展开时被冲开。期望控制展开门的打开，以便提供安全气囊通过内部板的通畅展开（例如，最小化破碎或没有碎片）。通常，围绕展开门的内部板区域被刻线或预先削弱，例如经由激光刻线、机械刻线等，以形成促进安全气囊的通畅展开的缝口。此外，内部板后面的支撑结构可附接到展开门以进一步控制展开门的打开。
在授予Yasuda等人的美国专利7,484,752中公开的一个例子中，易碎的分离轮廓形成为沿仪表板的背面的矩形形状，以限定在安全气囊展开期间打开的门部段。包含安全气囊的安全气囊设备被安装在加固构件和安全气囊支撑框架上。加固构件和安全气囊支撑框架沿门部段且围绕门部段被焊接到仪表板的背面。在焊接期间，加固构件和安全气囊支撑框架沿一轴线前后振动，以将加固构件和安全气囊支撑框架附接到基板。遗憾的是，一些仪表板设计具有在门部段周围或附近的相对非常轮廓化的表面，其可限制使得加固构件和安全气囊支撑框架沿一轴线前后振动以将安全气囊设备附接到仪表板所需的空间。
因此，期望提供用于机动车辆的具有一体式安全气囊门的内部板以及制造这类内部板的方法，其容许在有限的空间内和/或沿非常轮廓化的基板表面将安全气囊设备支撑结构焊接到基板。此外，根据结合附图和本背景技术描述的以下详细描述，本发明的其他期望特征和特点将变得显而易见。
发明内容
本文提供了用于机动车辆的具有一体式安全气囊门的内部板以及制造这类内部板的方法。根据示例性实施例，一种用于机动车辆的具有一体式安全气囊门的内部板包括基板，基板具有从中延伸通过的开口。安全气囊滑槽门组件包括至少部分地包围内部空间的滑槽壁。滑槽壁被配置为在展开期间引导安全气囊通过所述内部空间朝向所述开口传送。门翼片部分可枢转地连接到滑槽壁并至少部分地覆盖所述开口。周边凸缘从滑槽壁远离所述内部空间延伸。周边凸缘包括将周边凸缘附接到基板的一个或多个第一焊接特征。所述一个或多个第一焊接特征是沿第一方向延伸的细长特征。周边凸缘部段支架邻近滑槽壁的与内部空间相对的第一侧放置。周边凸缘部段支架包括将安全气囊滑槽门组件附接到基板的一个或多个第二焊接特征。所述一个或多个第二焊接特征是沿大致横向于第一方向的第二方向延伸的细长特征。
根据另一示例性实施例，提供制造用于机动车辆的具有一体式安全气囊门的内部板的方法。所述方法包括将安全气囊滑槽门组件的周边凸缘的一个或多个第一焊接特征焊接到基板上以将周边凸缘附接到基板的步骤。所述一个或多个第一焊接特征是沿第一方向延伸的细长特征。将周边凸缘部段支架的一个或多个第二焊接特征附接到基板上，以将安全气囊滑槽门组件附接到基板。一个或多个第二焊接特征是沿大致横向于第一方向的第二方向延伸的细长特征。
附图说明
下面将参照以下附图描述本发明，其中相似的附图标记表示相似的元件，在附图中：
图1是根据示例性实施例的用于机动车辆的包括一体式安全气囊门的内部板的一部分的平面图；
图2是沿线2-2截取的图1所示的内部板的竖直剖视图；
图3是沿线3-3截取的图1所示的内部板的水平剖视图；
图4是根据示例性实施例的安全气囊滑槽门组件和周边凸缘部段支架的平面图；以及
图5是根据示例性实施例的制造用于机动车辆的具有一体式安全气囊展开门的内部板的方法的流程图。
具体实施方式
以下具体实施方式在本质上仅是示例性的，并且无意限制本发明或本发明的应用和用途。此外，本发明不受在以上背景技术中或以下详细描述中呈现的任何理论限制。
本文构想到的各个实施例涉及用于机动车辆的具有一体式安全气囊门的内部板以及制造这类内部板的方法。本文教导的示例性实施例提供一种包括基板的内部板，基板具有从中延伸通过的开口。安全气囊滑槽门组件包括包围内部空间的滑槽壁。滑槽壁被配置为在展开期间引导安全气囊通过所述内部空间朝向所述开口传送。门翼片部分可枢转地连接到滑槽壁，以用于至少部分地覆盖所述开口。周边凸缘从滑槽壁远离所述内部空间延伸。周边凸缘包括将周边凸缘附接到基板的一个或多个第一焊接特征。在示例性实施例中，所述一个或多个第一焊接特征是沿第一方向延伸的细长特征，从而使得在第一焊接操作期间，周边凸缘可沿第一方向前后振动以将周边凸缘附接到基板。
周边凸缘部段支架邻近滑槽壁的与内部空间相对的一侧定位。周边凸缘部段支架包括将安全气囊滑槽门组件附接到基板的一个或多个第二焊接特征。在示例性实施例中，所述一个或多个第二焊接特征是沿大致横向于第一方向的第二方向延伸的细长特征，从而使得在第二焊接操作期间，周边凸缘部段支架可沿第二方向前后振动以将安全气囊滑槽门组件附接到基板。已经有利地发现，通过利用多个焊接操作将安全气囊滑槽门组件附接到基板，每个焊接操作均具有与相应焊接特征的前后振动方向的不同方向，从而允许在相对有限的空间内和/或沿相对非常轮廓化的基板表面将安全气囊滑槽门组件附接到基板。
图1是根据示例性实施例的内部板10的一部分的平面图。图2是沿线2-2截取的图1所示的内部板10的竖直剖视图。在示例性实施例中，内部板10是可位于机动车辆的驾驶员座椅和前排乘客座椅前方的仪表板。因此，图1和2描绘了前排乘客座椅前方的内部板10的视图。替代性地，内部板10可以是门板或其他内部车辆装饰板。如图所示，内部板10包括基板11、安全气囊滑槽门组件14和安全气囊模块16，所述安全气囊模块16包含可展开的安全气囊18和充胀器20。
在示例性实施例中，基板11由PP/TPO材料30形成。如在此使用的，术语“PP/TPO材料”指的是含有聚丙烯（PP）和/或热塑性烯烃（TPO）的材料。在示例性实施例中，PP/TPO材料30是包括PP和/或TPO作为主要成分的材料。除PP和/或TPO之外，PP/TPO材料30还可包括一种或多种其他组分，诸如橡胶、填充物（诸如滑石等）、冲击改性剂、稳定剂、加工添加剂和/或脱模剂、强化纤维（诸如玻璃纤维、天然纤维等）、抗刮添加剂、染料和/或着色成型添加剂、附着力促进剂、可回收产品等。本领域技术人员已知的其他组分也可包括在PP/TPO材料30中。在示例性实施例中，PP/TPO材料30是这样等级的PP/TPO材料，其具有相对高的机械性能，包括在23℃下至少约1500MPa的弯曲模量（诸如从约1500至约3000MPa，例如从约1600至约2600Mpa），并且适于形成仪表板基板。仪表板基板等级的PP/TPO材料的非限制性例子是位于俄亥俄州的Sydney的Advanced Composites股份有限公司制造的ATX832TM、ATX880TM和ATX639TM。还可从各种其他供应商商购许多其他合适等级的PP/TPO材料。
基板11的外表面12可以是硬装饰表面，诸如着色成型表面、涂漆表面等。替代性地，外表面12可被泡沫和蒙皮覆盖，诸如采用众所周知的现场发泡或三层层压结构，以提供“软仪表板”。
基板11的背面22被刻线或预先削弱以限定缝口24，缝口24形成沿水平方向是长边的矩形形状。中心缝口24a在横向侧26之间延伸以分割矩形形状，从而形成“H形图案”。缝口24和24a限定一体式安全气囊门28，其沿缝口24和24a与基板11分开并以对开方式打开，从而允许安全气囊18展开并膨胀到内部板10外侧，以促进安全气囊的通畅展开。替代性地，基板11的背面22可被刻线或预先削弱以限定没有中心缝口24a的缝口24，从而形成“U形图案”。可以使用本领域技术人员已知的用于预先削弱基板11以形成一体式安全气囊门的其他图案和缝口配置。
在示例性实施例中，利用激光刻线工艺形成缝口24和24a。在一个例子中，通过将光束直径为约0.1至约0.5mm并且波长为约10.6μm的激光束辐射到基板11的背面22上来形成缝口24和24a，以产生具有部分地穿透基板11的深度的点状狭缝孔。替代性地，可利用机械刻线或本领域技术人员已知的任何其他基板预先削弱工艺来形成缝口24和24a。
安全气囊滑槽门组件14附接到基板11的背面22。安全气囊滑槽门组件14包括滑槽部分32、门翼片部分34和36以及分别将门翼片部分34和36可枢转地连接到滑槽部分32的铰链38和40。在示例性实施例中，门翼片部分34和36被配置为“H形图案”门布局，其有助于一体式安全气囊门28以对开方式打开，从而促进安全气囊的通畅展开。滑槽部分32具有至少部分地包围内部空间44的滑槽壁42。内部空间44定尺寸为在安全气囊展开期间允许安全气囊18朝向门翼片部分34和36以及一体式安全气囊门28传送。安全气囊模块16附接到滑槽壁42，所述安全气囊模块容纳处于折叠状态的安全气囊18。如图所示，安全气囊模块16具有多个钩子74，所述钩子74向外突出通过滑槽壁开口76以与滑槽壁42接合。安全气囊模块16利用螺栓和螺母80经由支撑构件82附接到横向构件78。
门翼片部分34和36包括门翼片部段50和52。在示例性实施例中，铰链38和40分别一体地连接到门翼片部段50和52以及滑槽壁42，从而限定“活动铰链”。滑槽部分32包括滑槽壁42和从滑槽壁42的端部48远离内部空间44延伸的周边凸缘46。
在示例性实施例中，并且如图所示地，门翼片部段50和52、铰链38和40、滑槽壁42和周边凸缘46形成为由与PP/TPO材料30成分不同的TPE材料72制成的注塑成型一件式结构。TPE材料72是弹性体的且相对柔顺，并且在较大温度范围内（例如从约-30℃至约115℃）具有相对高的伸长率且在低温下（例如约-30℃）具有延展性。TPE材料72可以是包括苯乙烯成分、烯烃成分、尿烷成分、共聚酯成分或其结合的热塑性材料。替代性地，TPE材料72可以是热塑性硫化橡胶（TPV）。在示例性实施例中，TPE材料72在23℃下具有约25%或更大（诸如，从约25%至约500%，例如从约50%至约300%）的相对高的伸长率。在示例性实施例中，TPE材料72在23℃下具有约1000MPa或更小（诸如约500MPa或更小，例如从约1MPa至约100Mpa）的相对低的弯曲模量。TPE材料72有助于在安全气囊展开期间门翼片部段50和52、铰链38和40、滑槽壁42和周边凸缘46吸收能量并控制一体式安全气囊门28和安全气囊模块16的运动。合适的TPE材料的非限制性例子包括位于乔治亚州的德卢斯的Kraiburg TPE Corporation公司制造的各种等级的HIPEX®和Thermolast® TPE材料。也可从其他供应商商购许多其他合适的TPE材料。
在示例性实施例中，周边凸缘46以及门翼片部段50和52各自具有用于将周边凸缘46以及门翼片部段50和52分别附接到基板11的多个焊接特征84（例如，形状配合特征或肋）。具体地并还参照图3，焊接特征84是沿一方向（由双向箭头86指示）延伸的细长特征，从而使得经由沿方向86振动焊接特征84而能够将焊接特征84焊接到基板11的背面22，以将安全气囊滑槽门组件14附接到基板11。如图所示，在示例性实施例中，周边凸缘46包括在方向86上沿周边凸缘部段88、90和92延伸的多个焊接特征84，而另一周边凸缘部段94不包括沿方向86延伸的任何焊接特征84。因此，周边凸缘部段88、90和92经由焊接特征84被直接焊接到基板11，而周边凸缘部段94未被直接焊接到基板11。
参照图1和3-4，如图所示，周边凸缘部段94与基板11的轮廓化表面部段96（例如，弯曲表面）相邻地定位。在示例性实施例中，为了有利地简化模制过程，周边凸缘部段94被模制为具有相对“如所模制的”平坦情况98（由虚线指示）并且经由周边凸缘部段支架100被推靠在轮廓化表面部段96上。在示例性实施例中，周边凸缘部段支架100邻近滑槽壁42的侧面100放置并且具有沿大体横向于方向86的方向（由双向箭头106指示）延伸的细长的多个焊接特征104。在示例性实施例中，根据基板11的轮廓，方向106与方向86成约45至135°的角度，诸如约60至120°、诸如约75至105°、例如约90°的角度。
在示例性实施例中，周边凸缘部段94具有面对基板的表面108、与面对基板的表面108相反的背面110以及形成为通过周边凸缘部段94的开口112。如图所示，周边凸缘部段支架100沿背面110放置，并且焊接特征104延伸通过开口112，从而使得焊接特征104是凸起的并可以直接附接到与面对基板的表面108相邻的基板11的背面22上。在示例性实施例中，开口112被配置为并列狭缝，并且焊接特征104被配置为相应地延伸通过并列狭缝的肋。有利地，此配置促进通过开口112将焊接特征104振动焊接到基板11的背面22。
在示例性实施例中，根据基板11的形状，周边凸缘部段支架100可终止于周边凸缘部段94的最外侧边缘114，或替代性地可延伸经过最外侧边缘114以限定周边凸缘部段支架100的悬垂部分116（由虚线指示）。如图所示，悬垂部分116包括沿方向106延伸的细长的额外焊接特征118，所述额外焊接特征118附接到基板11并且与周边凸缘部段94的最外侧边缘114相邻。有利地，此配置增强安全气囊滑槽门组件14和基板11之间的联接，以有助于将展开能量集中于使安全气囊18向前通过一体式安全气囊门28。
在示例性实施例中，周边凸缘部段支架100进一步包括位于与限定焊接特征104的表面相反的表面上的定位器凸耳特征120。有利地，定位器凸耳特征120有助于将周边凸缘部段支架100定位在振动焊接固定件中，以便将周边凸缘部段支架100振动焊接到基板11上，从而促进可制造性。
在示例性实施例中，周边凸缘部段支架100由与TPE材料72成分不同的PP/TPO材料122形成。在示例性实施例中，PP/TPO材料30和122具有相同或大致等价的成分。如在此使用的，术语“相同或大致等价的成分”表示两种材料的成分相同，或者两种材料是在成分方面的差异在通常的混合/制造容差内的相同等级或等价等级的PP/TPO材料，或者两种材料是在成分方面的差异在通常的混合/制造容差内和/或达按重量计次要成分总计占总成分的约5%或更少的类似等级的PP/TPO材料。因此，PP/TPO材料30和122具有类似的物理性质（包括熔点）、机械性能（包括弯曲模量）和加工性能（包括溶体流动）和焊接性能。已经发现，将周边凸缘部段支架100焊接到基板11的各个区域（其中焊接特征104（以及可选地，118）和基板11由类似的PP/TPO材料形成）会导致稳健的焊接过程，其在周边凸缘部段支架100和基板11之间产生具有相对高的焊接强度的焊接接头。
参照图5，提供了根据示例性实施例的制造用于机动车辆的的具有一体式安全气囊门的内部板的方法150的流程图。方法150包括：将安全气囊滑槽门组件的周边凸缘的一个或多个第一焊接特征焊接到基板（步骤152），以将周边凸缘附接到基板。一个或多个第一焊接特征是沿第一方向延伸的细长特征。将周边凸缘部段支架的一个或多个第二焊接特征焊接到基板（步骤154），以将安全气囊滑槽门组件附接到基板。一个或多个第二焊接特征是沿大体横向于第一方向的第二方向延伸的细长特征。
尽管已经在本公开的以上详细描述中描绘了至少一个示例性实施例，但应该明白，存在大量变型。还应该明白，示例性实施例仅是例子，并且不以任何方式限制本公开的范围、应用或配置。反而，以上详细描述将为本领域技术人员提供用以实现本公开的示例性实施例的方便的路线图。应该理解，在不脱离所附权利要求中所述的本公开的范围的情况下，可对示例性实施例中所描述的元件进行功能和布置上的各种改变。

Claims (13)

1.一种用于机动车辆的具有一体式安全气囊门的内部板，所述内部板包括：
基板，其具有从中延伸通过的开口；
安全气囊滑槽门组件，其包括：
滑槽壁，其至少部分地包围内部空间并且被配置为在展开期间引导安全气囊通过所述内部空间朝向所述开口传送；
门翼片部分，其可枢转地连接到所述滑槽壁并至少部分地覆盖所述开口；
从所述滑槽壁远离所述内部空间延伸的周边凸缘，所述周边凸缘包括将所述周边凸缘附接到所述基板的一个或多个第一焊接特征，其中，所述一个或多个第一焊接特征是沿第一方向延伸的细长特征；以及
邻近所述滑槽壁的与内部空间相对的第一侧放置的周边凸缘部段支架，周边凸缘部段支架包括将所述安全气囊滑槽门组件附接到所述基板的一个或多个第二焊接特征，其中，所述一个或多个第二焊接特征是沿大致横向于第一方向的第二方向延伸的细长特征。
2.如权利要求1所述的内部板，其中，所述周边凸缘具有从所述滑槽壁的所述第一侧远离所述内部空间延伸的第一凸缘部段和从所述滑槽壁的第二侧远离所述内部空间延伸的第二凸缘部段，其中，所述第二凸缘部段包括所述一个或多个第一焊接特征，并且所述第一凸缘部段被牢固地定位在所述基板和所述周边凸缘部段支架之间。
3.如权利要求2所述的内部板，其中，第一凸缘部段具有面对基板的表面、与面对基板的表面相反的背面以及一个或多个开口，所述一个或多个开口在所述第一凸缘部段中穿过地形成并且从所述面对基板的表面延伸到所述背面，并且其中，所述周边凸缘部段支架沿所述背面的至少一部分放置并且延伸通过所述一个或多个开口，以将所述一个或多个第二焊接特征放置在所述面对基板的表面附近。
4.如权利要求3所述的内部板，其中，所述一个或多个第二焊接特征包括多个第二焊接特征，并且所述一个或多个开口包括多个并排狭缝，并且其中，所述第二焊接特征相应地放置通过所述并排狭缝并附接到所述基板。
5.如权利要求4所述的内部板，其中，所述并排狭缝沿大致横向于所述第一方向的第二方向延伸。
6.如权利要求3所述的内部板，其中，所述周边凸缘部段支架延伸经过所述第一凸缘部段的最外侧边缘，以限定所述周边凸缘部段支架的悬垂部分，并且其中，所述悬垂部分包括沿第二方向延伸的细长的额外第二焊接特征，所述额外第二焊接特征附接到所述基板并与所述第一凸缘部段的最外侧边缘相邻。
7.如权利要求1所述的内部板，其中，所述周边凸缘部段支架具有前表面和与前表面相反的背面，其中，所述一个或多个第二焊接特征沿所述前表面放置，并且其中，所述周边凸缘部段支架进一步包括沿所述背面放置的定位器凸耳特征。
8.如权利要求1所述的内部板，其中，所述基板包括第一PP/TPO材料，并且所述周边凸缘部段支架包括第二PP/TPO材料，并且其中，所述第一PP/TPO材料和第二PP/TPO材料具有相同或大致等价的成分。
9.如权利要求8所述的内部板，其中，所述安全气囊滑槽门组件包括与所述第一PP/TPO材料和第二PP/TPO材料在成分上不同的TPE材料。
10.如权利要求1所述的内部板，其中，所述滑槽壁具有从中通过地形成的多个开口，以用于将安全气囊模块附接到所述滑槽壁。
11.如权利要求1所述的内部板，其中，在所述安全气囊滑槽门组件附近对所述基板进行刻线，从而形成限定一体式安全气囊门的缝口。
12.如权利要求1所述的内部板，进一步包括：
能够操作性地附接到所述滑槽壁的安全气囊模块，以在展开期间引导安全气囊通过所述内部空间朝向所述基板传送。
13.一种制造用于机动车辆的具有一体式安全气囊门的内部板的方法，所述方法包括步骤：
将安全气囊滑槽门组件的周边凸缘的一个或多个第一焊接特征焊接到基板上，以将所述周边凸缘附接到所述基板，其中，所述一个或多个第一焊接特征是沿第一方向延伸的细长特征；以及
将周边凸缘部段支架的一个或多个第二焊接特征附接到所述基板上，以将所述安全气囊滑槽门组件附接到所述基板，其中，所述一个或多个第二焊接特征是沿大致横向于所述第一方向的第二方向延伸的细长特征。
CN201510123632.1A 2014-05-28 2015-03-20 机动车辆的具有一体式安全气囊门的内部板及其制造方法 Expired - Fee Related CN105270312B (zh)

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