CN105313821A - 具有脊柱式增强焊接轨道的主动垫式安全气囊 - Google Patents

具有脊柱式增强焊接轨道的主动垫式安全气囊 Download PDF

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CN105313821A
CN105313821A CN201510287949.9A CN201510287949A CN105313821A CN 105313821 A CN105313821 A CN 105313821A CN 201510287949 A CN201510287949 A CN 201510287949A CN 105313821 A CN105313821 A CN 105313821A
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CN105313821B (zh
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布兰登·阿塞拉格
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Ford Electric Mach Technology Nanjing Co ltd
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Abstract

本发明涉及一种具有脊柱式增强焊接轨道的主动垫式安全气囊。一种用于机动车辆的内饰表面的主动垫式安全气囊具有含在内表面上的闭环结合部的塑料成型的外部饰板。塑料成型的可膨胀的气囊构件具有配置为附接到车辆的支撑结构的中央附接部，沿周边边缘的结合凸缘，和在中央附接部分和结合凸缘之间的挡板部。闭环结合部和结合凸缘配置为限定在其间的实质上闭合环形区域。附接主体在原位被模塑来实质上地填充环形区域。由于环形区域中附接主体的原位模塑，所以饰板和气囊构件通过附接主体来结合，得到高结合强度。

Description

具有脊柱式增强焊接轨道的主动垫式安全气囊
背景技术
本发明总体上涉及用于机动车辆中乘员碰撞保护的主动垫式安全气囊，并且，更具体地，涉及增加在各自模塑的可膨胀的气囊构件和饰壁之间结合的稳健性。
主动垫式安全气囊是车辆乘员保护设备，其具有可充气的气囊以吸收冲击和减少在碰撞过程中对乘员的创伤。相对于一旦充气从各种开口的后面中出现的可展开的安全气囊衬垫，主动垫式安全气囊使用内饰表面本身来在碰撞事件开始时展开，用于吸收冲击和通过充气气体的作用消散能量。美国专利号8,205,909，公告日期2012年6月26日的美国专利，其通过引用并入本文，公开了一种集成到重量轻和视觉上有吸引力的手套箱门中的主动膝部垫式安全气囊。美国专利号8,474,868，公告日期2013年7月2日的美国专利，其也通过引用并入本文，公开了一种典型的结构，其中主动垫式安全气囊包括面对车辆乘员的外壁或饰板，其沿密封周边附接到内壁或板。壁的一个或两个是可变形的是为了提供可充气的气囊。例如，内壁可以具有褶状的(即，折叠状的)区域，其在充气过程中拉直。壁在它们的预展开非充气的情况下时最初隔开较小量。这允许充气气体以可以以实现整个面板均匀充气的方式进入。
典型的主动垫式安全气囊的内壁和外壁由模塑的热塑性塑料比如聚乙烯，聚烯烃或PVC(聚氯乙烯)组成。它们典型地被注塑成型但也可以被吹塑成型。当分别形成时，壁必须在它们周边的周围密封地连接是为了形成可充气的气囊。连接必须是强有力的以抵抗由于充气过程中的高压导致的分离。
一种密封气囊壁的已知方法是通过热焊接，其涉及加热匹配的表面且然后压缩它们在一起。示例包括热板焊接，红外焊接和激光焊接。总体上平面的焊接凸缘已经在内(气囊)壁的外部周边的周围提供，该焊接凸缘通过外(饰)壁的总体上平面的表面接收。外壁和/或内表面上也可以包括直立的密封肋，其在热焊接过程中通过穿透和熔接焊接凸缘或其它相对的表面增加焊接强度，其中被焊接的区域加热并且然后被压缩。尽管有密封肋的渗透，但是焊接分离仍继续对主动垫式安全气囊是潜在的故障模式。
发明内容
在本发明的一个方面中，主动垫式安全气囊提供用于机动车辆的内饰表面。塑料成型的外部饰板具有在内表面上的闭环结合部。塑料成型的可膨胀气囊构件具有配置为附接到车辆的支撑结构的中央附接部，沿周边边缘的结合凸缘，和在中央附接部和结合凸缘之间的挡板部。结合部或结合凸缘中的至少一个包括多个外周肋。结合部和结合凸缘通过使它们熔合在一起在热焊接区域中混合。脊柱式构件嵌入成型(insertmolded)到结合部或结合凸缘中的一个。脊柱式构件在相邻的外周肋之间突出，其中脊柱式构件通过结合部和结合凸缘之间的热焊接是不熔化的，以便结合部和结合凸缘的混合在热焊接区域中封装脊柱式构件的突出部分。
附图说明
图1是本发明可以应用到的类型的现有技术的主动膝部垫式安全气囊手套箱门系统的向外看的分解透视图。
图2是现有技术主动垫式安全气囊的外部饰板和气囊壁总成的后部透视图。
图3是去除气囊壁的图2的现有技术外部饰板的透视图。
图4是在饰板和气囊壁之间的现有技术焊接接头的剖视图。
图5是在嵌入模塑到外部饰板中之前具有工形梁横截面的脊柱式构件的一个实施例的透视图。
图6是沿图5的线6-6的脊柱式构件的剖视图。
图7是在热焊接之前，外部饰板，嵌入成型的脊柱式构件，和内部气囊壁的一个实施例的剖视图。
图8是在热焊接之后图7的外部饰板，脊柱式构件，和内部气囊壁的剖视图。
图9是具有T形横截面的脊柱式构件的另一实施例的透视图。
图10是沿线10-10的图9的脊柱式构件的剖视图。
图11是在外部饰壁中嵌入成型的图9的脊柱式构件的剖视图。
图12-14是具有其它横截面形状的脊柱式构件的其它实施例的剖视图。
图15是主动垫式安全气囊的另一实施例的剖视图，其中外部饰壁和内部气囊壁每个具有嵌入成型的脊柱式构件。
图16是在热焊接之后具有互锁的脊柱式构件的图15的主动垫式安全气囊的剖视图。
具体实施方式
现在参照图1，现有技术主动膝部垫式安全气囊系统10具有底板组件11，其形成用于垫式安全气囊的支撑结构或基座。底板11是通过来自如图1所示的储存腔或手套箱12中的铰链附接到车辆的手套箱门的一部分。可选择地，主动垫式安全气囊可以安装到另一支撑结构，例如，在转向柱下方的仪表板支撑。这样的位置接合到在车辆内的相应的座椅位置中驾乘的个人的膝盖。垫式安全气囊也可以放置用于保护其它身体区域，比如垫式安全气囊安装在用于躯干保护的乘客门上。
底板11充当用于支撑通过在它们的周边连接的内壁(气囊构件)13和外(饰板)壁14形成的可充气的气囊的反作用表面。壁13和14优选由模塑的塑料(比如热塑性聚烯烃(TPO))组成并且通过塑料焊接比如热板焊接连接，以在中央区域17的周围形成周边密封从而形成气囊。充气气源(即充气机)16被电子地控制，用来在碰撞过程中激活以释放气体来使垫式安全气囊充气。外壁14可以包含A类内饰表面比如手套箱门的外部，或额外的表层或覆盖物可以应用到它的外表面。
图2是可充气的气囊20的另一现有技术实施例的后视图。塑料成型的外部饰板壁21覆盖塑料成型的可膨胀的内部气囊壁22。壁21和22在闭合周边区域23的周围被连接，以形成具有在壁21和22之间的开放中央容积的可充气的气囊来在碰撞事件过程中从安装在气囊壁22的凹口25中的充气机24中接收充气气体。气囊壁22包括多个褶，比如26和27，以在充气过程中容纳气囊壁22的膨胀。多个凸台或塔28用来安装气囊壁22到充当反作用表面的车辆支撑结构。焊接凸缘29在气囊壁22的周围周向地延伸。包含切割穿过气囊壁22的星号状图案的通气孔30可以被包括，以用于在展开之前和期间为中央容积排气。其它种类的通气孔，比如主动通气口，也可以被采用。
图3显示了去除内部气囊壁的外壁21，其暴露了在组装时面对内壁的气囊表面31。多个直立肋32沿着闭合的周边区域23并通过热焊接连接内部气囊壁22(图2)的凸缘29以创建用于可充气的气囊的密封。肋33提供用于支撑充气机。
图4更详细地说明了在凸缘29和肋32之间的焊接接头。由于热和压力的应用，肋32优选穿透和结合凸缘23。在充气过程中，外壁21向外移动同时褶27展开。气囊膨胀导致应用到焊接处的力，其趋向剥离开焊接。
为了避免已知的焊接接头的某些缺点，本发明采用了脊柱式构件，其嵌入成型到被热焊接的壁中的一个，以便脊柱式构件以加强焊接的方式结合到热焊接区域中。
脊柱式构件35的第一实施例在图5和6中被显示，其形成为具有工形梁横截面的外周环。脊柱式构件优选由金属形成，比如不锈钢或铝或在热焊接塑料气囊和饰壁时在采用的温度处保持不熔化的非金属材料。如图6所示，工形梁横截面包括下或嵌入式板36，上板37，和在板36和37之间的中央腹板38。脊柱式构件35具有环形外周是为了沿着在主动垫式安全气囊壁的一个中通过外周肋限定的焊接轨道。
优选地，脊柱式构件35的尺寸适合于匹配如图7所示的一对相邻的外周肋的内部。因此，外部饰壁40具有由通过介入间隙43分开的肋41和42组成的结合部分。脊柱式构件35的下板36在壁40的制造过程中被嵌入成型以便脊柱式构件在肋41和42之间突出，上板37暴露(优选地保持在间隙43的轮廓内)。内部气囊壁45具有在热焊接过程中通过相邻区域47的加热与肋41和42热焊接的结合凸缘46。如本领域已知的，热焊接板或其它热源放置在结合部(肋41和42)和结合凸缘46之间以接触和熔化相应的塑料材料。一旦熔化或软化，则加热板被去除且然后壁40和45被压缩是为了混合熔化的塑料材料。如图8所示，壁在热焊接区域48中通过混合熔化在一起。脊柱式构件35是未熔化的，以便壁40和45中的塑料材料的混合封装在外周肋之间最初突出的脊柱式构件35的部分。因此，上板37通过混合壁40和45中的材料封装，同时下板36保持嵌入在壁40不熔化的部分中。脊柱式构件的突出进入到的相邻的肋之间的间隙提供用于两壁中的塑料材料的混合的空间，从而创造焊接，其实质上由于通过脊柱式构件增强而增加强度。
图9和10显示了具有T形横截面的脊柱式构件50的另一实施例。中央支柱52与上板51连接。如图11所示，中央支柱52通过嵌入模塑而嵌入到相邻的外周肋54和55之间的外饰壁53中来突出进入间隙56中，以便上板51向朝向与肋54和55热焊接的第二壁(未示出)。
图12显示了在脊柱式构件的横截面中的变化，其中中央腹板60耦接下板61和上板62。上板62具有一对延伸63和64，其被定向来穿透和夹紧到如流动到上板62下方的热焊接塑料材料的混合区域。以类似的方式，图13显示了替代实施例，其中中央支柱65连接具有成角的延伸部67和68的弯曲上板66以夹紧热焊接的混合塑料材料来进一步增加焊接强度。
图14显示了具有与锁定端部71集成的支柱的脊柱式构件的另一版本。端部71具有倾斜边缘73和凸缘72，其在图15和16所示的实施例中特别有用，其中脊柱式构件在外饰壁和内部气囊壁之间利用来以互锁方式热焊接。因此，图15显示了具有形成结合部的外周肋76和77和介入间隙78的外饰壁75。脊柱式构件80被嵌入成型，它的锁定端部84延伸到间隙78。内部气囊壁82具有结合凸缘82，在其中脊柱式构件83被嵌入成型，以便互锁端部85向间隙78突出。在热焊接过程中，结合凸缘82和肋76和77被加热到它们的熔点且壁75和81被压缩，脊柱式构件端部84和85沿着它们的成角面滑动直到它们卡合在一起并如图16所示锁定。结合凸缘和壁81和85的外周肋结合部分的塑料材料的混合，各自地封装互锁脊柱式构件。因此，热焊接区域的结合强度又进一步增加。
脊柱式构件的许多其它的横截面形状也可以使用，比如箭头或倒刺形形状。脊柱式构件优选形成外周环是为了加强用于主动垫式安全气囊的气囊周围的整个焊接轨道。然而，脊柱式构件还可以在外周结合区域的仅仅较小的弧形部分上使用是为了仅仅加强那些区域，在那儿集中的力可以增加焊接分离的可能性。

Claims (10)

1.一种用于提供机动车辆的内饰表面的主动垫式安全气囊，包含：
塑料成型的外部饰板，其具有在内表面上的闭环结合部；
塑料成型的可膨胀的气囊构件，其具有配置为附接到车辆的支撑结构的中央附接部，沿周边边缘的结合凸缘，和在中央附接部和结合凸缘之间的挡板部，其中结合部和结合凸缘中的至少一个包括多个外周肋，且其中结合部和结合凸缘通过将它们熔合在一起在热焊接区域中混合；以及
脊柱式构件，其嵌入成型到结合部或结合凸缘中的一个内，以在相邻的外周肋之间突出，其中脊柱式构件不被结合部和结合凸缘的热焊接所熔化，以便结合部和结合凸缘的混合在热焊接区域中封装脊柱式构件的突出部分。
2.根据权利要求1所述的主动垫式安全气囊，其中脊柱式构件是外周环。
3.根据权利要求1所述的主动垫式安全气囊，其中脊柱式构件由金属组成。
4.根据权利要求1所述的主动垫式安全气囊，其中脊柱式构件具有含通过中央腹板连接到上板的下板的工形梁横截面，其中下板在嵌入成型过程中被嵌入，且其中上板在热焊接区域中被封装。
5.根据权利要求1所述的主动垫式安全气囊，其中脊柱式构件具有含中央支柱和上板的T形横截面，其中中央支柱在嵌入成型过程中被嵌入，且其中上板在热焊接区域中被封装。
6.根据权利要求1所述的主动垫式安全气囊，其中脊柱式构件包含在外部饰板中注塑成型的第一脊柱式构件；并且
其中主动垫式安全气囊进一步包含在气囊构件中嵌入成型的第二脊柱式构件，且其中第一和第二脊柱式构件通过结合部和结合凸缘的混合封装。
7.根据权利要求6所述的主动垫式安全气囊，其中第一和第二脊柱式构件配置有在结合部和结合凸缘的热焊接过程中互锁的匹配的锁扣特征。
8.一种主动垫式安全气囊，包含：
饰板，其具有闭环结合部；
气囊构件，其配置为附接到车辆且包括沿周边边缘的结合凸缘和结合凸缘的径向内侧的挡板部；以及
脊柱式构件，其嵌入成型到饰板或气囊构件，并具有在热焊接区域中通过混合结合部和结合凸缘来封装的突出部分。
9.根据权利要求8所述的主动垫式安全气囊，其中闭环结合部包括从饰板的内表面中突出的外周肋，并且其中脊柱式构件在饰板中嵌入成型以在外周肋之间突出。
10.根据权利要求8所述的主动垫式安全气囊，进一步包含用于在饰板和气囊构件之间递送充气气体来使主动垫式安全气囊充气的充气机。
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