CN105835822B - 具有热焊铆钉部的主动垫 - Google Patents

具有热焊铆钉部的主动垫 Download PDF

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CN105835822B
CN105835822B CN201610051617.5A CN201610051617A CN105835822B CN 105835822 B CN105835822 B CN 105835822B CN 201610051617 A CN201610051617 A CN 201610051617A CN 105835822 B CN105835822 B CN 105835822B
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active pad
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布兰登·M·阿塞拉格
肖恩·B·韦斯特
斯泰西·H·瑞恩斯
詹姆斯·哈德利·缪特
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Ford Global Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1632—Laser beams characterised by the way of heating the interface direct heating the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B29C65/609—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being plunge-formed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2022/00—Hollow articles
    • B29L2022/02—Inflatable articles
    • B29L2022/027—Air bags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R2013/0287—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners integrating other functions or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
    • B60R2021/0407—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings using gas or liquid as energy absorbing means

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  • Electromagnetism (AREA)
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  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)
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Abstract

一种用于机动车辆的主动垫，所述垫包括具有位于内表面上的焊接轨道的塑料成型外饰板和塑料成型可扩展气囊元件，该塑料成型可扩展气囊元件具有沿着外围边沿具有朝向饰板内表面的第一表面和第二相对表面的焊接凸缘。焊接轨道和焊接凸缘通过热焊部接合以形成密封腔。为了形成机械加固焊接部的铆钉部，可以在焊接凸缘上分布多个沉孔。每个沉孔由穿透第一表面的颈部和穿透第二表面的头部组成。每个头部包括从颈部横向延伸的内凸台。热焊部包括从焊接轨道流过每个颈部且蔓延到每个头部中的内凸台上的塑料成型材料。

Description

具有热焊铆钉部的主动垫
背景技术
本发明总体涉及用于机动车辆内乘员碰撞保护的主动垫，并且更具体地涉及增加单独成型且之后热焊在一起的可扩展气囊元件和饰壁之间的接合稳固性。
主动垫是具有充气腔的车辆乘员保护装置，充气腔用于在碰撞期间吸收碰撞作用且降低对乘员的伤害。与充气时从各种开口后方出现的可展开安全气囊垫相反，主动垫在碰撞事件开始时使用内饰表面自身扩展以通过充气气体动作吸收碰撞作用且分散能量。这里通过引用而引入的公告日为2012年6月26日的美国专利8,205,909公开了一种集成在杂物箱盖内的主动式膝垫，该主动式膝垫质量轻且视觉上吸引人。这里同样通过引用而引入的公告日为2013年7月2日的美国专利8,474,868公开了一种典型结构，其中主动垫包括朝向车辆乘员沿密封周边附接到内壁或面板的外壁或饰板。为了提供充气腔，一个或两个壁是可变形的。例如，内壁(即气囊壁)可以具有在充气期间拉直的褶皱(即手风琴状)区域。当处于它们的预展开、未充气状况时，壁最初间隔开一小量。这容许充气气体以能够在整个面板实现均匀充气的方式进入。
典型的主动垫的内壁和外壁由成型的热塑性塑料组成，例如聚乙烯、聚烯烃或聚氯乙烯(PVC)。它们通常是注塑成型，但也可以吹塑成型。当单独成型时，壁必须围绕它们的周边气密地接合，从而形成充气腔。接合处必须牢固以抵抗充气期间的高压所产生的分离。
已知的使气囊壁密封的方法是通过热焊，热焊涉及配合表面的加热以及之后将它们压缩在一起。示例包括热板焊接、红外(IR)焊接和激光焊接。总体上平面的焊接凸缘设置在内(气囊)壁的外周边，其由外(饰)壁的总体上平的表面接收。外壁和/或内表面也可以包括直立的焊接肋，该焊接肋通过在热焊加工过程期间穿过焊接凸缘或其他相对表面并且与其熔合来增加焊接强度，在热焊加工过程中加热并且之后压缩将要被焊接的区域。尽管这些肋穿透，但焊缝分离一直是主动垫的潜在失效模式，这是由于包括将要被焊接部的翘曲、在焊接期间热板的温度变化、在焊接期间未修正所施加压力的误差以及由不同塑料制剂成型的饰壁和气囊壁之间的特征差异。
在充气期间的各种应力也会导致焊接失效的可能性。由于使褶皱的气囊壁充气需要弹性，在扩展期间焊缝被施加明显的剥离应力。另一应力源是气体发生器的气流起爆所引起的振动波。在充气期间整个气囊结构的扭曲和不均匀的膨胀会在特定的焊接位置(例如沿焊接部的长直边)产生应力或使存在的应力集中。
发明内容
在本发明中，通过使用同时产生将焊缝机械地固定在一起的整体铆钉部的结构和方法，外饰壁和内气囊壁之间的结合强度增加优于仅通过热焊所产生的材料熔合实现的强度。
在本发明的一方面，提供一种用于机动车辆内饰表面的主动垫。塑料成型外饰板具有位于内表面上的焊接轨道。塑料成型的可扩展气囊元件具有配置用于附接到车辆支撑结构的中心附接部、沿着外围边缘具有朝向饰板内表面的第一表面和第二相对表面的焊接凸缘以及位于中心附接部和焊接凸缘之间的褶皱区。焊接轨道和焊接凸缘通过热焊部接合以形成密封腔。多个沉孔分布在焊接凸缘上，其中每个沉孔在第一和第二表面之间延伸。每个沉孔由穿透第一表面的颈部和穿透第二表面的头部组成。每个头部包括从颈部横向延伸的内凸台。热焊部包括塑料成型材料，该塑料成型材料从焊接轨道流过每个颈部且蔓延到每个头部中的内凸台上。
根据本发明，提供一种主动垫，包含：
饰板，该饰板具有外围焊接轨道；以及
褶皱气囊元件，该褶皱气囊元件可附接到车辆且包括与焊接轨道热焊的外围凸缘；
其中沉孔分布在焊接凸缘上，沉孔包含各自的颈部和头部，其中热焊部包括从焊接轨道流过每个颈部并且遍布于每个头部中的内凸台上的塑料材料。
在本发明的一个实施例中，焊接轨道和焊接凸缘限定外围环，并且其中沉孔围绕外围隔开而平分外围环。
在本发明的一个实施例中，颈部和头部限定各自的圆柱。
在本发明的一个实施例中，各自的颈部和头部是同轴的。
在本发明的一个实施例中，内凸台平行于第一表面。
在本发明的一个实施例中，内凸台相对于第一表面倾斜。
根据本发明，提供一种制造用于主动垫的充气腔的方法，包含下列步骤：
成型具有位于内表面上的焊接轨道的塑料饰板；
成型塑料气囊元件，该塑料气囊元件具有配置用于附接作用面的中心附接部、沿着外围边缘具有朝向饰板内表面的第一表面和第二相对表面的焊接凸缘以及位于中心附接部和焊接凸缘之间的褶皱区，其中沉孔在焊接凸缘中成型，沉孔包含各自的颈部和头部；
加热焊接凸缘和焊接轨道以熔化位于第一表面和焊接轨道的外表面处的塑料材料；
抵靠焊接轨道压缩焊接凸缘使焊接轨道熔化后的塑料材料足以流过颈部进入头部；以及
冷却饰板和气囊元件，以使焊接轨道的固化材料在沉孔内形成铆钉部。
在本发明的一个实施例中，加热步骤由下列组成：
将焊接凸缘和焊接轨道对齐；
将辐射热源定位在焊接凸缘和焊接轨道之间；
激活辐射热源；以及
取回辐射热源。
在本发明的一个实施例中，辐射热源是热板。
在本发明的一个实施例中，焊接轨道和焊接凸缘限定外围环，并且其中沉孔围绕外围隔开而平分外围环。
在本发明的一个实施例中，颈部和头部限定各自的圆柱。
在本发明的一个实施例中，各自的颈部和头部是同轴的。
在本发明的一个实施例中，每个头部包括从颈部横向延伸的内凸台，并且其中内凸台平行于第一表面。
在本发明的一个实施例中，每个头部包括从颈部横向延伸的内凸台，并且其中内凸台相对于第一表面倾斜。
附图说明
图1是现有技术的主动垫总成的分解透视图，该总成包括饰板前壁和后气囊壁；
图2是图1的饰板前壁内表面的后透视图；
图3是示出现有技术的气囊元件的后透视图，该元件通过热焊组装到图2的饰板上；
图4是本发明的气囊元件的平面图，其具有在热焊之前分布到焊接凸缘上方的多个沉孔；
图5是图4的气囊元件在热焊之后的平面图；
图6是沿图4的线6-6的焊接凸缘的剖视图；
图7是沿图4的线7-7的焊接凸缘的剖视图；
图8-10示出根据本发明的方法用于产生整体铆钉部的热焊过程的剖视图；
图11A和11B分别是具有圆柱形颈部和头部的沉孔的剖视图和俯视图；
图12是沉孔的供选择的形状的俯视图；
图13A和13B分别是具有倾斜凸台的沉孔的剖视图和俯视图。
具体实施方式
图1-3示出了现有技术中以内饰板形成的主动垫，内饰板是机动车辆内的杂物箱盖的一部分。更具体地，饰板10用作接收可扩展气囊壁11的前饰板壁。面板10具有内表面12，内表面12具有优选地以从内表面向上延伸的肋形成的焊接轨道或滚道13，从而与气囊壁11的外凸缘14结合(例如通过如热板焊接的塑料焊接)。
气囊壁11具有位于中心附近用于安装气体发生器(未示出)的凹部15以及设置在中心附接部内用于将总成附接到例如杂物箱盖的内板(未示出)的作用面的多个安装塔16。在塔16和外凸缘14之间形成褶皱区17，以便一系列的褶皱在充气期间可以以容许饰板10向乘客舱移动以缓冲对乘客的碰撞的方式展开。
轨道13和凸缘14的热焊形成了从气体发生器接收充气气体的气囊腔。在热焊操作期间，可以使用热板、激光或其他热源来熔化轨道13和凸缘14的塑料材料，并且在移除热源之后，轨道13和凸缘14可以被压到一起并且冷却，以使熔化的材料混合并且焊接在一起，产生如图3所示的总成。
图4示出了本发明的气囊元件20，其中焊接凸缘21围绕气囊元件20形成外围环。气囊元件20进一步包括位于焊接凸缘21和中心附接部23之间的褶皱区22。为了形成多个整体铆钉部，多个沉孔24分布在焊接凸缘21上，穿透焊接凸缘21的相对面。优选地，沉孔24可以围绕外围均匀地分开，以使沉孔24的中心将焊接凸缘21的外围环平分。
如图6和7所示，每个沉孔在上表面25和下表面26之间延伸以形成孔，塑料材料在热焊期间从饰板上的焊接轨道流过该孔，如下面所述。每个沉孔24由各自的颈部27和头部28组成。颈部27和头部28优选地是同轴的并且可以具有圆柱状形状。头部28穿透上表面25且具有比颈部27更大的直径，从而提供从颈部27径向向外延伸的内凸台29。在图6和图7中，内凸台29与下表面26大体上平行。颈部27穿透下表面26，以在热焊期间为源自饰板的熔化的塑料材料提供流动通道。
因此，沉孔24的目的是在热焊期间接收来自前饰板上的焊接轨道的塑料材料流，其中熔化的塑料材料流过每个颈部且在遍布于每个头部中的内凸台上以形成整体铆钉部，该整体铆钉部用于增加焊缝的机械强度。本发明用于热焊主动垫总成的方法优选包括使用注塑成型来单独成型塑料饰板和塑料气囊元件。如图8所示，具有沉孔24的气囊元件20与饰板30适当地对齐，以使焊接凸缘21的第一表面26与饰板30的焊接轨道31对齐。辐射热源32(例如热板或激光发生器)放置在表面26和焊接轨道表面31之间。为了熔化表面26和31处的塑料材料层而激活热源32。之后收回热源32并且压缩焊接凸缘21和饰板30，如图9所示。压缩的结果是相面对的表面的塑料材料混合，从而形成常规的热焊部。此外，焊接轨道31在沉孔24颈部27附近熔化的塑料材料在压缩期间流过各自的颈部27，其流动量足以流入头部28并且蔓延到内凸台29上。最后，冷却饰板和气囊元件，以使固化后的焊接轨道材料在沉孔内形成铆钉部。
图10是示出了已形成的热焊结合部33的剖视图，热焊结合部33将焊接凸缘21和饰板30未熔化的塑料材料接合。热焊熔化部33延伸进入每个沉孔24内以形成整体铆钉部35，整体铆钉部35在沉孔24的头部28内扩展，以便通过各自的内凸台29和围绕每个颈部27较窄的塑料材料机械地固定每个铆钉部。图5示出了分布在焊接凸缘21外围上方的已形成的整体铆钉部35。如图5所示，铆钉部35可以在整个外围上方形成或可以仅用在需要另外加固以承载充气力的区域。由于沉孔24可以在气囊元件的初始注塑成型期间形成，因此在不增加部件或不增加程序的情况下可以获得增加的接合强度。
沉孔24可以根据除图4-10中示出的优选的圆柱状(盘状)形状之外的多种可替换的轮廓形成。例如，图11A和11B中的沉孔40具有椭圆轮廓的头部41和颈部42。图12是示出了具有成形为矩形长方体(盒状)的头部44和颈部45的沉孔43的俯视图。沉孔43的侧剖视图表现为与图11A所示的剖面一致。在每种情况下，为了提供用于接收从颈部蔓延的塑料材料的内凸台，头部具有比颈部更大的轮廓。
图13A和13B示出了供选择的实施例，其中头部由准圆柱状轮廓形成。更具体地，沉孔46由具有倾斜的外缘48和相对于焊接凸缘的下表面倾斜的内凸台50的头部47组成。倾斜的表面可以提供在沉孔46内形成的铆钉部的头部的更大联锁。

Claims (10)

1.一种提供机动车辆内饰表面的主动垫，包含：
塑料成型的外饰板，所述外饰板具有位于内表面上的焊接轨道；以及
塑料成型的可扩展气囊元件，所述气囊元件具有配置用于附接到所述车辆的支撑结构的中心附接部、沿着外围边缘具有朝向所述内表面的第一表面和相对的第二表面的焊接凸缘以及位于所述中心附接部和所述焊接凸缘之间的褶皱区，其中所述焊接轨道和所述焊接凸缘通过热焊部接合以形成密封腔；
其中，多个沉孔分布在所述焊接凸缘上，其中每个所述沉孔在所述第一表面和所述第二表面之间延伸，其中每个所述沉孔由穿透所述第一表面的颈部和穿透所述第二表面的头部组成，并且其中每个所述头部包括从所述颈部横向延伸的内凸台；
其中所述热焊部包括塑料成型材料，所述塑料成型材料从所述焊接轨道流过每个所述颈部且蔓延到每个所述头部中的所述内凸台上。
2.根据权利要求1所述的主动垫，其中所述焊接轨道和所述焊接凸缘限定外围环，并且其中所述沉孔围绕外围隔开而平分所述外围环。
3.根据权利要求1所述的主动垫，其中所述颈部和所述头部限定各自的圆柱。
4.根据权利要求3所述的主动垫，其中各自的所述颈部和所述头部是同轴的。
5.根据权利要求1所述的主动垫，其中所述内凸台平行于所述第一表面。
6.根据权利要求1所述的主动垫，其中所述内凸台相对于所述第一表面倾斜。
7.一种主动垫，包含：
饰板，所述饰板具有外围的焊接轨道；以及
褶皱气囊元件，所述褶皱气囊元件可附接到车辆且包括与所述焊接轨道热焊的外围的焊接凸缘；
其中沉孔分布在所述焊接凸缘上，所述沉孔包含各自的颈部和头部，其中热焊部包括从所述焊接轨道流过每个所述颈部并且遍布于每个所述头部中的内凸台上的塑料材料。
8.根据权利要求7所述的主动垫，其中所述焊接轨道和所述焊接凸缘限定外围环，并且其中所述沉孔围绕外围隔开而平分所述外围环。
9.根据权利要求7所述的主动垫，其中所述颈部和所述头部限定各自的圆柱。
10.根据权利要求9所述的主动垫，其中各自的所述颈部和所述头部是同轴的。
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