CN105966343B - 具有热焊接到反作用板的气囊元件的主动垫 - Google Patents

具有热焊接到反作用板的气囊元件的主动垫 Download PDF

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CN105966343B
CN105966343B CN201610115524.4A CN201610115524A CN105966343B CN 105966343 B CN105966343 B CN 105966343B CN 201610115524 A CN201610115524 A CN 201610115524A CN 105966343 B CN105966343 B CN 105966343B
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attachment
reaction plate
balloon element
weld
boss
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CN105966343A (zh
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凯特林·M·西施克
斯泰西·H·瑞恩斯
尼古拉斯·安德鲁·马佐基
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Ford Global Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • 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
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    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/20—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components
    • B60R21/205—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components in dashboards
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B29C65/1403—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 characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
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    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种用于机动车辆的主动垫包括在碰撞过程中向外展开的塑料成型装饰壁。塑料成型反作用板被安装为展开基部。塑料成型气囊元件围绕大体上密封的周边与装饰壁接合以形成充气腔。气囊元件包括围绕中心附接区域的至少一个大体上周向的褶状挡板。中心附接区域包括朝向反作用板上的附接衬垫突出以形成热焊缝的附接凸台。附接凸台具有拱形横截面，该拱形横截面限定具有尖端的焊缝表面。焊缝表面被热焊接到附接衬垫，以使尖端首先与附接衬垫接触，其中气囊元件与反作用板的压缩形成接触边缘，该接触边缘从尖端径向向外移动以从热焊缝排出气体。

Description

具有热焊接到反作用板的气囊元件的主动垫
技术领域
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，并且，更具体地，涉及一种具有充气腔的主动垫，该充气腔通过热焊接到塑料壁的反作用板的塑料壁面板成形。
背景技术
主动垫是一种车辆乘员保护装置，该装置具有充气腔以在碰撞过程中吸收碰撞并且减少对乘员的伤害。相对于一充气就从各种开口后面显露出来的由各种织物制成的可展开的安全气囊垫，主动垫使用内饰表面本身来在碰撞事件开始时膨胀，用于吸收碰撞并且通过充气气体的动作来消散能量。通过引用并入本文的公告日期为2012年6月26日的美国专利8,205,909公开了一种集成到重量轻且在视觉上有吸引力的杂物箱盖中的主动垫。也通过引用并入本文的公告日期为2013年7月2日的美国专利8,474,868公开了一种典型的结构，其中主动垫包括面对车辆乘员的前壁或饰板，该前壁或饰板沿密封的周边附接到气囊元件。一个或两个壁是可变形的以便提供可膨胀、充气腔。例如，气囊元件可以具有在充气过程中拉直的褶状挡板(即，手风琴状)区域。壁可以在它们的预展开、未充气状况时最初地隔开一小量。这允许充气气体以实现穿过面板的均匀充气的方式进入。
典型的主动垫的气囊的前壁和后壁由成型热塑性塑料比如聚乙烯、聚烯烃、或聚氯乙烯(PVC)制成。它们典型地注射成型但也可以吹塑成型。当单独地成形时，前壁和后壁必须围绕它们的周边密封地接合以便形成充气腔。接合处必须是强有力的以抵抗由在充气过程中高充气压力造成的分离和当乘员碰撞垫时导致的分离。外围密封部通过例如热焊接成形。热焊接包含加热配合表面并且然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。
气囊元件通常安装到充当固定展开基部的反作用板，以使饰板在气囊元件膨胀时朝向乘客向外移动。反作用板也可以由成型热塑性塑料制成，并且在反作用板和气囊元件之间的接合处可以通常通过热焊接来形成。一种普遍类型的主动垫是内置于杂物箱盖中的乘客膝垫。在这种情况下，反作用板也形成盖的内壁(例如，结合盖闩锁和其它部件)。
在气囊元件和反作用板上的相容(即，互补)表面已设置用于被热焊接在一起。表面通常是平坦的(即，平面的)，但也可以包括可以穿透到配合表面中的直立肋。在平坦表面中的缺陷(例如，凹坑或其它变形)可以存在，原因在于与注射成型过程相关的材料缺陷或问题(例如，模具磨损)。变形的存在可以是在热焊缝内捕捉气体(即，大气)的袋。捕捉的气泡形成可以降低焊缝强度的焊接点中的薄弱点。
发明内容
本发明使用轻微弯曲的焊接表面，以使本应被捕捉的气体在焊接过程中在部件的压缩过程中向外移位(远离焊缝界面)。
在本发明的一个方面中，主动垫安装在机动车辆中乘客舱的内饰表面。塑料成型装饰壁在朝向乘客舱中的乘客的展开方向上展开。塑料成型反作用板安装为展开基部，并且板具有平面附接衬垫。塑料成型气囊元件围绕大体上密封的周边与前壁接合，以形成在碰撞事件过程中接收充气气体的充气腔。气囊元件包括围绕中心附接区域的至少一个大体上周向的褶状挡板。中心附接区域包括朝向附接衬垫突出且形成热焊缝的附接凸台。附接凸台具有限定具有尖端的焊缝表面的拱形横截面。焊缝表面被热焊接到附接衬垫，以使尖端首先与附接衬垫接触，其中气囊元件与反作用板的压缩形成接触边缘，该接触边缘从尖端径向向外移动以从热焊缝排出气体。
附图说明
图1是一种类型的主动膝垫杂物箱盖系统向外看的分解立体图，本发明可以应用于这种类型的系统；
图2是主动垫的充气腔总成的后部透视图；
图3是示出了现有技术主动垫总成的侧剖视图；
图4是具有用于接收气囊元件的附接衬垫的内部杂物箱盖的后部透视图；
图5是具有用于接收气囊元件的肋状附接衬垫的内部杂物箱盖的后部透视图；
图6是内部杂物箱盖的剖视、透视图；
图7是现有技术的气囊元件的附接凸台的剖视图；
图8示出了在热焊接过程中的现有技术的附接塔和反作用板的互补、平面焊接表面；
图9是具有用于与平面反作用板接合的弯曲的焊接表面的本发明的附接凸台的剖视图；
图10示出了在弯曲的焊接表面和平面表面之间的热焊缝的成形，导致气体从焊缝排出；
图11是根据现有技术的另一个实施例的气囊元件的后部平面图；
图12是通过图11的附接凸台中的一个的剖视图；
图13是如图11的气囊元件的修改的改进的附接凸台的剖视图；
图14-16表示在图13的附接凸台的热焊接过程中的连续装配步骤。
具体实施方式
现在参照图1，现有技术的主动膝垫系统10具有形成垫的基础的基板部件11。基部11可以通过铰接从如图1中所示的存储腔或杂物箱12附接到车辆，或安装到另一个结构，例如，位于转向柱下方的仪表板支撑件。这样的位置容易接近乘坐在车辆内的相应的就座位置中的个人的膝盖。
在本实施例中，基部11是充当反作用表面的盖内壁或内衬，用于支撑充气腔，该充气腔通过后(气囊)壁13和前(装饰)壁14形成，后(气囊)壁13和前(装饰)壁14围绕它们的周边15接合。后(气囊)壁13和前(装饰)壁14优选由成型塑料(比如热塑性聚烯烃(TPO))制成，并且通过塑料热焊接——比如热板或振动焊接——接合，以围绕中心区域17形成外围密封部，从而形成充气腔。充气气体源16被电子地控制，用于在碰撞过程中激活，以释放气体来给垫充气。前(装饰)壁14可以包含A级内饰表面，比如杂物箱盖的外部，或者附加外壳或罩(未示出)可以应用于其外表面。
图2是一种已知类型的主动垫的充气腔20的后视图。塑料成型前装饰壁21覆盖塑料成型、可膨胀气囊元件22。塑料成型前装饰壁21和气囊元件22围绕闭合周边区域23接合，以形成具有开放中心腔的充气腔，该开放中心腔在塑料成型前装饰壁21和气囊元件22之间以在碰撞事件过程中接收来自安装在气囊元件22的凹部25中的充气机24的充气气体。气囊元件22包括多个褶皱部，比如26和27，以适应在充气过程中气囊元件22的膨胀。多个附接塔(即，凸台)28从设置在挡板褶皱部26和27内的气囊元件22的中心区域突出。凸台28用来将气囊元件22安装到反作用表面(未示出)。排气孔30由星形类型切口组成，其穿过气囊元件22以使气囊腔排气。
图3示出了包括周边地密封到气囊元件33的前装饰壁32的垫31的剖视图。气囊元件33包括焊接到反作用壁35的附接凸台34，该凸台34可以包含例如杂物箱盖内衬。在展开过程中，由于充气气体被供应到气囊腔36中，所以前装饰壁32在朝向车辆的乘客舱中的乘客的展开方向37上展开。在垫的展开之前、期间、和之后，热焊缝38将气囊元件33保持在反作用壁35上。气囊元件33的保持在所有三个阶段过程中是至关重要的。
图4示出了杂物箱盖的内壁40的平面图，该杂物箱盖起到用于主动垫展开的反作用板的作用。内表面41面对气囊元件并且可以形成为注射成型塑料部件。多个凸起肋42可以设置在内表面41上，用于加强内壁40。作为起到杂物箱盖的作用的一部分，闩锁43被安装在内壁40中的相应的插孔中。多个附接衬垫44-47设置为接收气囊元件上的各自的附接凸台。每个附接衬垫44-47具有适应于未焊接到各自的附接凸台的平坦、平面形状。图5示出了替代实施例，其中平坦、平面附接衬垫包括焊接肋。特别地，反作用板50具有内表面51，其中多个附接衬垫52-55每个包括从附接衬垫的平坦、平面表面突出的多个同心直立肋。肋增加热焊缝穿透到相应的附接凸台的表面中。
图6是具有含肋和不含肋的附接衬垫的另一个盖内壁/反作用板60的透视图。板60通过不含有肋的平坦附接衬垫61和62的剖视图。附接衬垫63和64也被示出，其中一系列肋65和66被使用。本发明适用于含有肋或不含有肋的附接衬垫。
图7示出了通过现有技术的附接凸台或塔70的剖视图，其中大体上平坦、平面表面71与将被热焊接到的反作用板上相应的附接衬垫的平坦、平面表面相符。
图8描绘了与反作用板72热焊接的附接凸台70，其中附接凸台70的平面表面71已由于热施加而被熔融。同样地，反作用板72的平面表面73被熔融并且部件将要被压缩，以便获得混合的熔融层，从而通过热焊缝接合部件。凹部74可以设置在附接凸台70的端壁中以接收过量的熔融材料并且形成附加机械互锁。由于使表面的所有部分在压缩过程中同时聚在一起的表面71和73的互补平面特征，所以气泡可以在如上所述的热焊接界面被捕捉。
为了减缓气泡形成的可能性，本发明采用具有如图9中所示的拱形横截面的附接凸台75上的焊接表面。因此，附接凸台75具有大体上直边的横截面，该直边朝向反作用板延伸并且具有焊缝表面76，该焊缝表面76具有包括在焊缝表面76的中心部的尖端77的弯曲轮廓。在优选实施例中，焊缝表面76在尖端77和外部边缘78之间是圆形的或弯曲的。为了提供拱形横截面，形成附接凸台75的端壁的厚度可以从在边缘78的厚度T1增加到在尖端77的更大的厚度T2。附接凸台75可以可选择地包括中心凹部79。在图9中，附接凸台75是总体上圆柱形塔，其中每个纵向横截面显示出相同的拱形横截面轮廓。作为从尖端77到边缘78的圆形形状的替代方案，可以使用直线斜率。此外，当附接凸台具有延伸的形状而不是塔时，尖端77可以轻微偏离中心或可以包括脊，如后面的实施例所述。
图10示出了焊接附接凸台75和反作用板80之间的热焊缝的形成，其中相对焊缝表面76和81由于加热处于熔融状态。由于凸台75的限定弯曲的焊缝表面76的拱形横截面，所以尖端77首先与附接衬垫表面81接触，并且随后的压缩形成接触边缘82，该接触边缘82在热焊缝的形成过程中远离尖端77径向向外移动以如通过箭头83所示从接近表面之间排出气体。在附接衬垫包括直立肋的情况下，径向向外移动的接触边缘可以包括每个肋的末端，热焊缝在该末端形成。
与圆柱形附接塔不同，凸台可以包括纵长通道形状，如图11和12中所示。气囊元件85包括限定在多个褶状挡板88内的中心附接区域中的附接凸台86和87。如图12中所示，附接凸台86远离气囊元件85的装饰壁边延伸了第一高度，同时褶状挡板88延伸了小于第一高度的第二高度。附接凸台86的增加的高度能够实现与反作用板的附接而不干扰褶状挡板88。
图13示出了用来避免使用如图11和12中所示的互补、平坦表面可以发生的捕捉的气泡形成的附接凸台86的横截面形状的修改。因此，附接凸台90具有含有拱形形状的横截面轮廓。拱形形状包括通过上壁93接合的剖面侧91和92，该上壁93限定焊缝表面94，该焊缝表面94朝向反作用板(未示出)的平面附接衬垫突出。焊缝表面94具有尖端95，该尖端95如中心脊沿纵长附接凸台90延伸。尖端95限定脊，气囊元件抵靠反作用板的压缩形成接触边缘，该接触边缘同样地从尖端95径向向外移动，以从热焊缝排出气体。
在图14-16中更详细地示出了使用纵长通道附接凸台的热焊缝的形成。反作用板100被对齐到邻近气囊元件的位置中，以使附接凸台90与附接衬垫101对准。热源比如热板102设置在焊缝表面94和附接衬垫101之间以熔化相应的表面。在熔化之后，热板102被撤回并且部件被移动到一起，如图15中所示。尖端95首先如图15中所示的接触，使得随着作为熔融层的焊缝表面94和附接衬垫101接合到一起，本应被捕捉的气体如通过箭头103和104所示从热焊缝排出。如图16中所示，在先前熔融层的压缩和随后的冷却之后形成热焊缝105以将气囊元件保持在反作用板上，而没有由捕捉到的气泡造成的薄弱区域。

Claims (9)

1.一种用于安装在机动车辆中乘客舱的内饰表面处的主动垫，包含：
塑料成型装饰壁，所述塑料成型装饰壁用于在朝向所述乘客舱中的乘客的展开方向上展开；
塑料成型反作用板，所述塑料成型反作用板安装为展开基部并且具有平面附接衬垫；以及
塑料成型气囊元件，所述塑料成型气囊元件围绕密封的周边与所述装饰壁接合以形成在碰撞事件过程中接收充气气体的充气腔，其中所述气囊元件包括围绕中心附接区域的至少一个周向的褶状挡板，其中所述中心附接区域包括附接凸台，
其特征在于，
所述附接凸台朝向所述附接衬垫突出并且形成热焊缝，其中所述附接凸台具有拱形横截面，所述拱形横截面限定具有尖端的焊缝表面；
其中所述焊缝表面被热焊接到所述附接衬垫，以使所述尖端首先与所述附接衬垫接触，并且其中所述气囊元件与所述反作用板的压缩形成接触边缘，所述接触边缘从所述尖端径向向外移动以从所述热焊缝排出气体。
2.根据权利要求1所述的主动垫，其中围绕所述尖端的所述焊缝表面是圆形的。
3.根据权利要求1所述的主动垫，其中所述附接凸台包含总体上圆柱形塔。
4.根据权利要求1所述的主动垫，其中所述附接凸台包含纵长通道形状。
5.根据权利要求1所述的主动垫，其中所述附接凸台从所述装饰壁延伸第一高度，并且其中所述褶状挡板从所述装饰壁延伸小于所述第一高度的第二高度。
6.根据权利要求1所述的主动垫，其中所述气囊元件包括多个附接凸台并且其中所述反作用板包括相应的多个附接衬垫。
7.根据权利要求1所述的主动垫，其中所述反作用板包括从所述附接衬垫延伸的穿透肋。
8.根据权利要求1所述的主动垫，包含杂物箱盖，其中所述反作用板形成所述杂物箱盖的内壁。
9.一种主动垫，包含：
反作用板，所述反作用板具有平面焊接衬垫；以及
气囊元件，所述气囊元件具有热焊接到所述衬垫的附接凸台；
每个凸台具有含有热焊接到各自衬垫的尖端的拱形横截面，以使所述尖端首先与所述衬垫接触并且其中所述气囊元件与所述反作用板的压缩形成接触边缘，所述接触边缘从所述尖端径向向外移动以从所述热焊缝排出气体。
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