CN106794817A - 用于安全气囊盖罩的复合材料 - Google Patents

用于安全气囊盖罩的复合材料 Download PDF

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CN106794817A
CN106794817A CN201580047861.8A CN201580047861A CN106794817A CN 106794817 A CN106794817 A CN 106794817A CN 201580047861 A CN201580047861 A CN 201580047861A CN 106794817 A CN106794817 A CN 106794817A
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composite
air bag
hinge
bag housing
polyester
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CN106794817B (zh
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M·霍因
A·罗林
R·舒尔茨维宁克
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Suzuki Motor Corp
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Abstract

本发明涉及一种用于安全气囊盖罩的复合材料(1)，其作为面状材料包括至少一个纺织层，所述盖罩构成至少一个具有铰链的活盖，所述纺织层在单面或双面设有塑料覆层(2)、尤其是膜，所述覆层具有比纺织层低的熔点，复合材料在铰链区域中沿铰链构成至少一个单折叠部或双折叠部(3)，在其中面状材料一次或两次以一个或两个侧面相互贴靠，在折叠部区域中覆层表面、尤其是膜表面相互贴靠并且通过之前或事后的热输入而熔化在一起。

Description

用于安全气囊盖罩的复合材料
技术领域
本发明涉及一种用于安全气囊盖罩的复合材料，其作为面状材料包括至少一个纺织层，所述盖罩构成至少一个具有铰链的活盖。
背景技术
已知由塑料制成的安全气囊盖罩，所述盖罩构成一个或两个活盖，所述活盖在三个边缘上分别具有规定断裂线并且在安全气囊触发后在那里裂开并且在第四边缘上构成铰链，活盖围绕该铰链翻转并且不在那里断开，从而确保活盖不飞入机动车内部空间中。活盖在铰链区域中的可靠保持通过铰链区域中附加的、未断开的纱线实现，例如由EP2057044所公开的。
此外，由DE 102012012315 A1公开了安全气囊盖罩活盖的铰链设有折叠/折叠部或者说环圈，所述折叠/折叠部或者说环圈在铰链打开时展开并且因此释放用于活盖的附加行程。该技术尤其是用于纺织面料、如织物(例如芳香聚酰胺或聚酯)中，以便能够在打开安全气囊时克服设置在仪表板中的、由载体填料、间隔介质(如泡沫或间隔编织物)和装饰材料引起的层厚度，从而使活盖打开得足够远，以致安全气囊可完全且无阻碍地展开，同时活盖不分离。通常在注塑过程本身中通过滑块设置环圈，所述滑块在向注塑模具中加入变形的材料后形成环圈。
该过程步骤是复杂的并且带有风险，因此作为替代方案在具有多个单个步骤的上游过程中设置环圈。在此环圈必须通过附加的保持系统(例如胶粘剂或接缝)来固定。该原理目前也是现有技术。但此过程费时并且基于多个加工步骤成本较高。
发明内容
本发明的任务在于以低的制造成本提供一种用于安全气囊盖罩的复合材料，在其中位于活盖铰链区域中的折叠部在注塑过程中防止熔体可能流入折叠部或者说环圈中。
根据本发明所述任务如下解决：
－纺织层在单面或双面设有塑料覆层、尤其是膜，所述覆层具有比纺织层低的熔点，
－复合材料在铰链区域中沿铰链构成至少一个单折叠部或双折叠部，在所述折叠部中面状材料一次或两次以一个或两个侧面相互贴靠，
－在折叠部区域中覆层表面、尤其是被覆层的表面、优选膜表面相互贴靠并且是通过热输入而熔化在一起的。
本发明涉及折叠部/环圈自身通过施加在表面上的覆层、尤其是膜(由热塑性材料制成)实现粘合，所述覆层通过热输入熔化并且通过作用于环圈的侧面压力相互粘合并且由此在没有附加加工步骤的情况下将引入的折叠部/环圈保持在适当的位置上。所有必要的加工步骤在制造折叠部/环圈期间进行。
该方法特别适合在热塑性复合材料(例如基于聚丙烯的自增强复合材料)用作安全气囊铰链时使用，所述材料为了(折叠)变形过程必须被加热并且通过压合折叠部/环圈相互粘合。在此折叠部/环圈借助位于表面上的面状材料——其位于整个材料表面上——在折叠部/环圈区域中彼此粘合，由此折叠部/环圈的位置和折叠深度/或环圈深度固定。
由此在包覆注塑过程中没有熔体能够到达环圈中，从而最佳地确保了环圈功能。当在注塑过程中有熔体进入环圈时，则颗粒飞行和环圈故障的风险非常高且不能控制。也不再需要对工具进行密封。
本发明的有利方案在从属权利要求中给出。
附图说明
在附图中示意性以剖面图示出并且在下面包括替代方案地详细说明本发明的一种实施例。附图如下：
图1为在设置折叠部/环圈之前单面设有覆层、尤其是膜的被加热的复合材料；
图2为设有折叠部/环圈的被加热的复合材料；
图3为压合/压紧折叠部/环圈之后的被加热的复合材料。
具体实施方式
安全气囊盖罩是由刚性和/或坚硬的、板状或幅状的塑料材料制成并且因此是相对薄的面状硬物且具有处处相等的厚度和有限的弹性(与膜相反)。
在此安全气囊盖罩由热塑性塑料材料、尤其是由热塑性聚丙烯(PP)制成。该材料优选是板状的自增强复合材料1(复合物/复合材料)，在其中均质聚丙烯膜、共聚聚烯烃膜、均质聚酯膜或共聚聚酯膜与其它加强层交替，所述其它加强层由聚丙烯带或聚酯带制成或含有聚丙烯带或聚酯带。在此所述带构成薄层，在其中所述带有序排列、尤其是如织物放置或交织，或者交叉和横向地无序排列。在所有情况下在下面被称为“织物层”。所述膜层和带层(加强层)相互交替并且带层的总数量为至少为两层、尤其是三至八层并且尤其是在总厚度为0.4mm至2mm、尤其是0.8至1mm时是三至八层。在压力和热输入的情况下所有层熔化成唯一的面状材料、优选板，该板仅由聚丙烯层或聚酯层制成。
其它位于膜层之间或位于膜层上的加强层在替代实施方案中代替带而具有纤维或纱线，所述纤维或纱线又由聚丙烯膜或聚酯膜制成并且有序(也作为织物)或无序排列。
复合材料1的上侧和/或下侧设有覆层2、尤其是设有热塑性膜，其尤其是由聚酯或聚丙烯或共聚聚烯烃层合而成。
在板状复合材料1中在晚些时候以下述方式引入一个或两个覆盖安全气囊的活盖，即，在复合材料内在每个活盖的三个边缘上设置规定断裂线，所述规定断裂线贯穿整个板并且在安全气囊触发后释放活盖。在第四边缘上设有细长的铰链区域，以便使活盖在触发后在不断开的情况下翻转。
通过下述方式防止断开，即在复合材料1中的铰链区域中成形至少一个折叠/折叠部/环圈3或一个沟槽，其沿铰链纵向延伸方向或者说活盖边缘在铰链中延伸并且由此产生横向于铰链纵向延伸方向的附加材料长度。铰链区域中的该附加材料长度在活盖围绕铰链翻转时提供足够的行程长度，从而确保活盖不断开。
为了产生折叠部(3)、折叠、环圈，优选使用加热的刀片(热刀)，该刀片被压入铰链区域中的复合材料中并且在此使热塑性材料变形，所述材料附加地在变形之前优选被局部或全表面地加热。
复合材料1、尤其是织物层形式的纺织层在单面或双面设有塑料覆层2、尤其是膜，所述覆层牢牢附着在复合材料、尤其是纺织层的表面上。塑料覆层、尤其是膜具有0.02至0.1mm、优选0.03至0.06mm的厚度。
在此塑料覆层2具有与复合材料1或纺织层相比低或相同的熔点。优选覆层的塑料或部分覆层已经在160℃以下、优选在125℃至155℃时熔化并且织物的塑料在160℃以上、优选从165℃起熔化。
在铰链区域中在复合材料1中沿铰链设置单折叠部3(V形折叠)或双折叠部(N形折叠)。在单折叠部中确保覆层2位于折叠部/折叠内，使得折叠部/折叠的内表面以其覆层相互贴靠。相反，当选择双折叠部时，则复合材料的两个外表面都设有覆层/膜。
在设置折叠之前，将材料加热到125℃至155°并且因此加热到这样的温度上，在该温度时材料可变形并且内侧表面可相互粘合，从而覆层熔化、但复合材料/其余的面状材料未熔化。由此折叠表面熔化并且在冷却后产生折叠/折叠部，所述折叠/折叠部不再具有自由空隙，在晚些时候的压力注塑时注塑塑料不能进入所述折叠/折叠部中。
通过选择特定的覆层材料或膜材料确保在安全气囊触发后并且在安全气囊活盖撕开和翻转时折叠/折叠部/环圈被可靠撕开，以便为活盖提供附加行程。
优选聚丙烯、共聚聚烯烃或聚酯用于覆层材料、尤其是膜材料。

Claims (11)

1.用于安全气囊盖罩的复合材料(1)，其作为面状材料包括至少一个纺织层，所述盖罩构成至少一个具有铰链的活盖，其特征在于，
－所述纺织层在单面或双面设有塑料覆层(2)、尤其是膜，所述覆层具有比纺织层低的熔点，
－复合材料(1)在铰链区域中沿铰链构成至少一个单折叠部或双折叠部(3)，在该折叠部中面状材料一次或两次以一个或两个侧面相互贴靠，
－在折叠部(3)区域中覆层(2)表面、尤其是膜表面相互贴靠并且通过之前或事后的热输入而熔化在一起。
2.根据权利要求1所述的复合材料，其特征在于，所述覆层的塑料在160℃以下、优选在125℃至155℃时熔化，并且织物的塑料在160℃以上、优选从165℃起熔化。
3.根据权利要求1或2所述的复合材料，其特征在于，所述复合材料(1)具有0.4至2mm、优选0.8至1.0mm的厚度，并且塑料覆层(2)具有0.02至0.1mm、优选0.03至0.06mm的厚度。
4.根据上述权利要求之一所述的复合材料，其特征在于，所述折叠部是V形或N形的。
5.根据上述权利要求之一所述的安全气囊盖罩，其特征在于，所述折叠部的沿铰链(3)延伸的狭长折叠面或折叠层相互紧靠成在折叠面或折叠层之间无空隙。
6.根据权利要求3所述的安全气囊盖罩，其特征在于，所述折叠面/折叠层相互平行。
7.根据上述权利要求之一所述的安全气囊盖罩，其特征在于，自增强的热塑性复合材料(1)包括多个上下叠置的、由热塑性聚丙烯或聚酯制成的层，由均质聚丙烯膜、含有共聚物的聚烯烃膜、均质聚酯膜或含有共聚物的聚酯膜构成的各层与加强层交替，在所述加强层中聚丙烯或聚酯是带状、纤维状或纱线状的，或所述加强层具有聚丙烯带或聚酯带和/或聚丙烯纤维或聚酯纤维和/或聚丙烯纤维或聚酯纱线。
8.根据权利要求7所述的安全气囊盖罩，其特征在于，在加强层中的由聚丙烯或聚酯制成的带、纤维或纱线构成织物。
9.根据权利要求7所述的安全气囊盖罩，其特征在于，在加强层中的所述带和/或纤维交叉和横向地无序排列。
10.根据上述权利要求之一所述的安全气囊盖罩，其特征在于，所述覆层(2)、尤其是膜由聚丙烯、共聚聚烯烃或聚酯制成。
11.根据上述权利要求之一所述的安全气囊盖罩，其特征在于，在盖罩材料中设有两个活盖作为双活盖并且在该双活盖的两侧各有一个铰链，所述铰链分别具有至少一个沿铰链延伸的折叠部。
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