CN106143390B - 用于覆盖气囊的车辆内饰板及其制造方法 - Google Patents

用于覆盖气囊的车辆内饰板及其制造方法 Download PDF

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CN106143390B
CN106143390B CN201610304856.7A CN201610304856A CN106143390B CN 106143390 B CN106143390 B CN 106143390B CN 201610304856 A CN201610304856 A CN 201610304856A CN 106143390 B CN106143390 B CN 106143390B
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vehicle interior
chute channel
cover plate
panel
opening
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CN106143390A (zh
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格温内尔·莫尼尔
杰罗姆·布尔布斯
蒂埃里·舒巴赫
法布里斯·佩平
约恩·博尼法斯
理查德·格南
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Faurecia Innenraum Systeme GmbH
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Abstract

本发明涉及一种用于覆盖气囊的车辆内饰板和一种制造用于覆盖气囊的车辆内饰板的方法。所述车辆内饰板包括：具有开口的基板、插入到所述开口中的溜槽通道组件、表皮、以及设置在所述表皮和所述基板之间的泡沫层。所述溜槽通道组件包括围绕用于所述气囊的溜槽通道的壁部和覆盖所述溜槽通道并闭合所述开口的盖板。所述盖板包括气囊门，其中，所述盖板的外表面与所述泡沫层接触。所述盖板的外表面具有粗糙表面结构，所述外表面具有至少4μm的表面粗糙度参数Ra。

Description

用于覆盖气囊的车辆内饰板及其制造方法
技术领域
本发明涉及用于覆盖气囊的车辆内饰板。此外，本发明涉及制造用于覆盖气囊的车辆内饰板的方法。
背景技术
已知提供具有集成的气囊门的现场发泡的内饰板。例如，DE 10 2014 010 860A1公开了内饰板，该内饰板包括基板、安装至基板的气囊溜槽门组件、表皮、和设置在表皮和基板之间的泡沫，其中，所述溜槽门组件包括设置有便于气囊完全展开的预先弱化件的门翼部。
然而，在展开气囊期间，气囊门的打开会导致泡沫的大量破裂。特别地，门翼部的快速加速会将泡沫的碎片弹射到车辆的内部空间中，造成了对乘客的安全危害。
发明内容
考虑到现有技术的前述状态，本发明的目的是提供一种用于覆盖气囊的改进的车辆内饰板及其相关的制造方法。特别地，本发明的目的是提供一种在气囊弹出的情况下提高乘坐机动车辆的乘客的安全性的内饰板。
这些目的是通过具有本发明的车辆内饰板和通过本发明的用于制造车辆内饰板的方法来实现。本发明的可选的其它特征和其它改进从本发明和结合附图的详尽说明将变得显而易见。
本发明包括用于覆盖气囊的车辆内饰板。所述车辆内饰板包括：具有开口的基板、插入到所述开口中的溜槽通道组件、表皮、以及设置在所述表皮和所述基板之间的泡沫层。所述溜槽通道组件包括围绕用于所述气囊的溜槽通道的壁部和覆盖所述溜槽通道并闭合所述开口的盖板。另外，所述盖板包括气囊门，其中，所述盖板的外表面与所述泡沫层接触。此外，所述盖板的外表面具有粗糙表面结构，所述外表面具有至少4μm的表面粗糙度参数Ra。通常，所述粗糙表面结构覆盖所述溜槽通道组件的与泡沫层接触的所有部分或至少整个气囊门。
所述表皮可以形成内饰板的最顶层，从而其从机动车辆的乘客舱是可见的。壁部被设计成在气囊展开期间引导气囊朝向气囊门通过溜槽通道。盖板和/或泡沫层和/或表皮可沿着气囊门的边缘和/或接缝部弱化，以确保气囊门在气囊展开的情况下打开。
表面粗糙度参数Ra以常规的方式来理解。为了确定Ra，针对外表面上的点的高度沿着横跨外表面的任意轮廓线获得一系列足够窄间隔的测量值。然后，表面粗糙度参数Ra被定义为测量值和该轮廓线的中线上的对应点之间的距离的算术平均数，所述距离在正交于所述中线的方向上测量到。该中线可以在比对应于表面粗糙度的高度变化大得多的横向尺寸上呈现弯曲。通常，中线的整个弯曲在从乘客舱观看时是凸的。
该粗糙表面结构导致了泡沫层和盖板的外表面之间的显著增强的粘接。当气囊门在气囊展开而打开时，该增强的粘接是有益的。首先，该增强的粘接使泡沫层的更完全地撕裂，从而产生更少量的碎片。其次，该增强的粘接防止碎片由于盖板的快速加速而落入到乘客空间中。
在一个实施方式中，溜槽通道组件为一件式注射模塑部件。在该情况下，壁部和盖板以单一的工艺步骤来制造。
所述溜槽通道组件可以由热塑性材料制成，热塑性材料例如包含聚丙烯、和/或聚乙烯、和/或含丙烯单元和/或乙烯单元的共聚物。
所述溜槽通道组件的材料包含作为添加剂的三元乙丙橡胶(ethylene propylenediene monomer，EPDM)是有用的，以使所述盖板更有弹性，尤其是在低温下更有弹性。这可以防止气囊门在气囊弹出的情况下以不可控的方式破裂。
通常，所述盖板的所述外表面的表面粗糙度参数Ra为至少6μm和/或至多13μm。在泡沫层和盖板的外表面之间的粘接方面，发现在6μm和13μm之间的表面粗糙度参数Ra产生所期望的改进。相较于用于车辆内饰应用的典型的注射模塑部件的表面(该表面并未被故意地粗糙化)，6μm的表面粗糙度参数Ra对应于明显更粗糙的表面。
所述盖板的所述外表面的粗糙表面结构可以具有至少300μm和/或至多700μm的最大幅度。该最大幅度被限定成在针对外表面上的点的高度沿着横跨外表面的轮廓线获得足够窄间隔测量值之后得以确定，该高度再次相对于中线而被定义。最大幅度被定义为因此而获得的测量值之间的最大差值。因此，最大幅度对应于最大峰值高度和最深谷底之间的高度差。当然，粗糙表面结构不需要并且通常也将不会是周期性的。
在典型的实施方式中，所述盖板的所述外表面具有峰值之间的至少100μm和/或至多800μm的平均间隔。在此，对峰值的定义需要测量值落在相邻的峰值之间的中线下方。
所述泡沫层优选地由聚氨酯制成。该材料被广泛地用于现场发泡的内饰板。
本发明还包括一种制造用于覆盖气囊的车辆内饰板的方法。所述方法包括以下步骤：提供具有内表面的第一模具。然后，使所述内表面粗糙化以形成粗糙表面结构。之后，利用第一模具通过注射模塑来制造溜槽通道组件。所述溜槽通道组件包括围绕溜槽通道的壁部和覆盖所述溜槽通道的盖板。在溜槽通道组件的制造期间，所述第一模具的所述内表面的粗糙表面结构形成所述盖板的外表面的粗糙表面结构。此外，提供具有开口的预模塑的基板。将所述溜槽通道组件插入到所述开口中，从而所述盖板闭合所述开口。将表皮和带有所述溜槽通道组件的基板置于第二模具中。最后，将泡沫材料注射到所述第二模具中以填充表皮和带有所述溜槽通道组件的基板之间的空间。
这样，形成了泡沫层，其接触盖板的外表面并且牢靠地将表皮连接至所述基板和所述溜槽通道组件。由于外表面的粗糙表面结构，因而所提出的制造方法良好地适于产生在盖板的外表面和泡沫层之间具有改进的粘接的车辆内饰板。
例如，通过喷砂或蚀刻可以实现所述内表面的粗糙化。
所述方法还可以包括火烧的步骤，其中在注射所述泡沫材料之前，将热量施加至所述盖板的外表面。该火烧导致了盖板的外表面的表面张力的增大。这样，可以实现盖板的外表面和仪表板的泡沫层之间的粘接的增强。通常，通过火烧对盖板的外表面的处理以如下这种方式执行：使得外表面的粗糙结构不被改变。
在此所描述的方法特别可用于制造如在上文中进一步描述的或在下文中更详尽地描述的车辆内饰板。
附图说明
在下文中，本发明的示例性实施方式将结合附图进行描述。
图1为根据示例性实施方式的车辆内饰板和气囊组件的截面视图；以及
图2为图1中描绘的实施方式的细节的放大图。
具体实施方式
图1中显示了车辆内饰板1和气囊组件2的实施方式。车辆内饰板1的所描绘的实施方式为位于机动车辆中乘客前方的仪表板。车辆内饰板1包括具有开口4的基板3和插入到开口4中的溜槽通道组件5。溜槽通道组件5为一件式注射模塑部件并且包括壁部6和具有外表面8的盖板7。溜槽通道9由壁部6和盖板7围绕。盖板7将基板3的开口4闭合并且包括具有第一门翼部11和第二门翼部12的气囊门10。门翼部11和门翼部12经由接缝部13连接。
基板3和盖板7被泡沫层14和表皮15覆盖，泡沫层14由聚氨酯制成。表皮15面向机动车辆的乘客座位。
气囊组件2包括可展开的气囊16、气筒17、以及将气囊组件2与溜槽通道组件5连接的钩部18和钩部19。气囊组件2利用螺栓21和螺母22附接至车辆的横梁20。
溜槽通道9容纳处于折叠状态的气囊16。壁部6被设计成当气囊16被展开时将气囊16导向气囊门10。随着气囊16撞击门翼部11和门翼部12，当门翼部11和门翼部12沿着接缝部13分开时，气囊门10打开。而且，在气囊16展开时，泡沫层14和表皮15在接近于接缝部13的区域中撕裂。表皮15和/或泡沫层还可以预先弱化以在气囊16展开期间沿着弱化线撕裂。在撕裂接缝部13、泡沫层14和表皮15之后，气囊16被允许完全地展开并且在机动车辆的乘客空间23中膨胀。
图1中的点划框24表示图2中描绘的细节的区域。图2中显示的特征利用与图1中相同的附图标记表示。所显示的溜槽通道组件5的盖板7覆盖基板3中的开口4。泡沫层14和表皮15覆盖基板3和盖板7，从而泡沫层14与基板3和盖板7接触。溜槽通道组件5可以利用模具通过注射模塑而制造，该模具通过在模塑工艺之前的喷砂或蚀刻而被粗糙化。用于制造溜槽通道组件5的材料为例如聚丙烯或聚乙烯或二者的共聚物的热塑性树脂(包含作为添加剂的EPDM)。由于模具的粗糙度，因而盖板7的外表面8具有如图2所示的粗糙表面。在制造溜槽通道组件5之后，可以火烧外表面8以增大其表面张力。在制造车辆内饰板1期间，将基板3和溜槽通道组件5与表皮15一起置于第二模具中。然后，将泡沫层14注射到第二模具中。由于外表面8的粗糙表面结构，外表面8和泡沫层14之间的接触区域增大。外表面8的表面粗糙度参数Ra可以为8μm，同时外表面的粗糙表面结构具有400μm的最大幅度和峰值之间的200μm的平均间隔。

Claims (12)

1.一种用于覆盖气囊的车辆内饰板（1），所述车辆内饰板（1）包括：
具有开口（4）的基板（3），
插入到所述开口（4）中的溜槽通道组件（5），
表皮（15），以及
设置在所述表皮（15）和所述基板（3）之间的泡沫层（14），
其中，所述溜槽通道组件（5）包括围绕用于所述气囊的溜槽通道（9）的壁部（6）和覆盖所述溜槽通道（9）并闭合所述开口（4）的盖板（7），所述盖板（7）包括气囊门（10），其中，所述盖板（7）的外表面（8）与所述泡沫层（14）接触，其特征在于，
使用粗糙的模具注射模塑所述盖板（7），使得所述盖板（7）的所述外表面（8）具有粗糙表面结构，所述外表面（8）具有至少4 µm的表面粗糙度参数Ra；
所述泡沫层（14）通过将泡沫材料注射到所述表皮（15）和所述基板（3）之间的空间内而形成。
2.如权利要求1所述的车辆内饰板（1），其特征在于，所述溜槽通道组件（5）为一件式注射模塑部件。
3.如权利要求1或2所述的车辆内饰板（1），其特征在于，所述溜槽通道组件（5）由包含聚丙烯、和/或聚乙烯、和/或含丙烯单元和/或乙烯单元的共聚物的材料制成。
4.如权利要求1所述的车辆内饰板（1），其特征在于，所述溜槽通道组件（5）由包含作为添加剂的三元乙丙橡胶的材料制成。
5.如权利要求1所述的车辆内饰板（1），其特征在于，所述盖板（7）的所述外表面（8）的表面粗糙度参数Ra为至少6 µm 和/或至多13 µm。
6.如权利要求1所述的车辆内饰板（1），其特征在于，所述盖板（7）的所述外表面（8）的所述粗糙表面结构具有至少300µm 和/或至多700 µm的最大幅度。
7.如权利要求1所述的车辆内饰板（1），其特征在于，所述盖板（7）的所述外表面（8）具有所述粗糙表面结构的峰值之间的至少100µm 和/或至多800 µm的平均间隔。
8.如权利要求1所述的车辆内饰板（1），其特征在于，所述泡沫层（14）由聚氨酯制成。
9.一种制造如权利要求1所述的用于覆盖气囊的车辆内饰板（1）的方法，所述方法包括以下步骤：
提供具有内表面的第一模具；
使所述内表面粗糙化以形成粗糙表面结构；
利用所述第一模具通过注射模塑来制造溜槽通道组件（5），所述溜槽通道组件（5）包括围绕溜槽通道（9）的壁部（6）和覆盖所述溜槽通道（9）的盖板（7），其中，所述第一模具的所述内表面的粗糙表面结构形成所述盖板（7）的外表面（8）的粗糙表面结构；
提供具有开口（4）的预模塑的基板（3）；
将所述溜槽通道组件（5）插入到所述开口（4）中，从而所述盖板（7）闭合所述开口（4）；
将表皮（15）和带有所述溜槽通道组件（5）的基板（3）置于第二模具中；以及
将泡沫材料注射到所述第二模具中以填充所述表皮（15）和带有所述溜槽通道组件（5）的基板（3）之间的空间。
10.如权利要求9所述的方法，其特征在于，通过喷砂或蚀刻实现所述内表面的粗糙化。
11.如权利要求9或10所述的方法，其特征在于，还包括火烧的步骤，其中在注射所述泡沫材料之前，将热量施加至所述盖板（7）的所述外表面（8）。
12.一种如权利要求9至11中任一项所述的方法用于制造如权利要求1至8中任一项所述的车辆内饰板（1）的用途。
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