CN107303853B - 具有连接气囊与装饰板的t形热焊缝的主动垫 - Google Patents

具有连接气囊与装饰板的t形热焊缝的主动垫 Download PDF

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CN107303853B
CN107303853B CN201710236581.2A CN201710236581A CN107303853B CN 107303853 B CN107303853 B CN 107303853B CN 201710236581 A CN201710236581 A CN 201710236581A CN 107303853 B CN107303853 B CN 107303853B
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weld
wall
skirt
neck member
flange
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CN107303853A (zh
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拉杰·S·罗伊乔杜里
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Ford Global Technologies LLC
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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
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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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
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    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/7392—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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Abstract

一种主动垫，安装在机动车辆的内部装饰表面上，用作撞击事件中的缓冲垫。主动垫具有塑料成型的可膨胀的气囊壁，气囊壁具有终止于裙部的同心褶皱。双侧焊接凸缘从裙部整体地延伸。塑料成型的装饰壁覆盖在气囊壁上。双侧焊接凸缘与装饰壁形成热焊缝，以提供在撞击事件期间接收充气气体的可充气空腔。双侧焊接凸缘包括成型为从裙部径向向外延伸的板构件和成型为大体上平行于裙部延伸的颈部构件。热焊缝使颈部部件偏转为从裙部径向向内延伸，使得颈部构件暴露于可充气的空腔，由此来自充气气体的压力将颈部构件压靠在装饰壁上。

Description

具有连接气囊与装饰板的T形热焊缝的主动垫
技术领域
本发明总体涉及用于机动车中乘客碰撞保护的主动垫，更具体地说，涉及一种使用T形焊接凸缘将充气气囊壁热焊接到装饰板上以增加焊接强度的主动垫。
背景技术
主动垫是具有气体充气气囊以在碰撞期间吸收撞击并减少对乘客的伤害的车辆乘员保护装置。与在充气后从各种开口后面出现的各种织物制成的可展开的气囊垫相反，主动垫在碰撞事件开始时使用内部装饰表面本身膨胀，以便通过充气气体排放吸收撞击和耗散能量。2012年6月26日授权的美国专利8,205,909(通过引用并入本文)公开了一种整合到轻量化和有视觉吸引力的手套箱门中的膝盖主动垫。2013年7月2日发布的美国专利8,474,868(也通过引用并入本文)公开了一种典型结构，其中主动垫包括前壁或装饰板，前壁或装饰板面向车辆乘员沿密封周边连接到后壁或气囊构件。气囊构件进一步附接到固定的作用表面，例如仪表板、门衬板、手套箱或框架元件。前壁和后壁中的一个或两个可变形，以便提供可膨胀的、可充气的气囊。例如，气囊构件可以具有在充气期间拉直的褶皱(即手风琴状)区域。当处在它们的预部署、未充气状态时，壁最初间隔开少量。这允许充气气体以实现整个装饰板的均匀充气的方式进入。
为了有助于保护车辆乘客的腿部，膝盖主动垫系统可以位于车辆的腿部空间区域附近。该系统可以具有形成主动垫的支撑结构或基座的基座面板部件。例如，基座可以是通过与储物腔或手套箱铰接而附接到车辆的手套箱门的一部分。或者，主动垫可以安装到另一个支撑结构，例如在转向柱下方的仪表板支撑件。这样的位置与乘坐在车辆内相应的就座位置的个人的膝盖相接触。也可以放置垫来保护其他身体区域，例如安装在乘客门上用于保护躯干免受内部撞击的垫。
用于主动垫的典型气囊的前壁和后壁由成型热塑性塑料(如聚乙烯、聚烯烃或PVC(聚氯乙烯))组成。它们通常注射成型为单独的部件。注射成型的优点包括可使用具有高强度和一致性的材料、生产具有良好配合和精加工的部件、以及可以使用不同材料和不同厚度的材料分别形成每个壁部件的性能。当单独形成时，前壁和后壁必须围绕其周边气密连接，以形成可充气的气囊。连接必须强固以抵抗可能由于在充气或当乘客撞击主动垫带来的高充气压力引发的分离。
密封囊壁的已知方法是通过热焊接，其涉及加热匹配表面，然后将它们压缩在一起。实例包括热板焊接、红外焊接和激光焊接。通常提供平面的焊接凸缘，其围绕内部气囊壁的外周边径向向外延伸，内部气囊壁焊接到外壁的大致平坦的表面。外壁表面还可以包括直立的密封肋，其通过在热焊接过程中穿过焊接凸缘而增加焊接强度，其中焊接凸缘和密封肋被加热然后被压缩。尽管密封肋的穿透力，但是焊接强度一直是主动垫的潜在弱点。
充气期间的应力可能导致在单独成型的结构之间的连接接头处的焊缝分离。由于焊缝的通常结构，在一些设计中，在气囊充气期间，在焊缝处可能会发生显着的剥离应力。人们希望降低剥离的可能性并因此产生更强的连接。
发明内容
在本发明的一个方面，用于安装在机动车辆的内部装饰表面上的主动垫包括具有终止于裙部的同心褶皱的塑料成型的可充气气囊壁。气囊壁包括从裙部整体延伸的双侧焊接凸缘。塑料成型的装饰壁覆盖在气囊壁上。双侧焊接凸缘与装饰壁形成热焊缝，以提供在撞击事件期间接收充气气体的可充气空腔。双侧焊接凸缘包括成型为从裙部径向向外延伸的板构件和成型为大体上平行于裙部延伸的颈部构件。热焊缝使颈部部件从裙部偏转向内延伸，使得颈部构件暴露于可充气的空腔，由此来自充气气体的压力将颈部构件压靠在装饰壁上。
附图说明
图1是包括装饰板前壁和后气囊壁的现有技术主动垫总成的透视分解图；
图2是图1的装饰板前壁的内表面的后透视图；
图3是表示通过热焊接组装到图2的装饰板上的现有技术的气囊构件的后透视图；
图4是本发明的主动垫的横截面视图，其中内壁包括限制充气气体被引导到焊缝中的阻挡肋；
图5和图6是在展开期间在相应膨胀阶段的褶皱区域和外壁的一部分的剖视图；
图7是本发明的T形热焊缝的剖视图；
图8和图9是使用热板同时熔化焊接凸缘的表面并径向向内重新定向颈部构件的过程的剖视图；
图10和11示出了将加热的焊接凸缘与装饰板的加热的焊接轨道接合以产生热焊缝的过程；
图12更详细地示出了焊接凸缘；
图13是具有在热焊缝的弯曲部分处的释放狭槽(relief slot)的颈部构件的气囊壁的透视图；
图14和15示出了由于形成热焊缝而导致的释放狭槽的顺序闭合；
图16是表示释放狭槽的布置的另一个实施例的图示；
图17是本发明方法的一个实施例的流程图。
具体实施方式
图1-3示出了形成为作为机动车辆中的手套箱门的一部分的内饰板的现有技术的主动垫。更具体地，装饰板10用作接收可充气气囊壁11的前装饰壁。面板10具有内表面12，其具有焊接轨道或滚道13，焊接轨道或滚道13优选地形成为从内表面向上延伸的肋，以便与气囊壁11的外部焊接凸缘14(例如通过诸如热板焊接的塑料焊接)接合。
气囊壁11具有靠近中心的凹部15，用于安装充气机(未示出)和设置在中心附接部分中用于将组件附接到反作用表面(例如手套箱门的内板(例如，图4中的门22))的多个安装塔16。褶皱区域17形成在塔16和焊接凸缘14之间，使得一系列褶皱在充气期间可以以允许装饰板10朝向客舱移位以缓冲撞击乘客的方式展开。
轨道13和凸缘14的热焊接产生用于从充气机接收充气气体的气囊腔。在热焊接操作期间，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，并且在热源被移除之后，轨道13和凸缘14被压在一起并冷却，熔化的材料混合并焊接在一起，导致如图3所示的组装。
如图4更详细所示，现有技术的组件采用L形热焊缝。更具体地，褶皱区域17终止于外裙部20，其后面具有大体上垂直于装饰板10的表面12延伸的大体上环形或管状形状。凸缘14从裙部20径向向外延伸以与轨道13热焊接。使用注射成型制造气囊壁11更为适合。使用向外延伸的凸缘14最容易适用于注射成型的使用，因为它避免了“模具锁定”问题。然而，所产生的L形焊缝在充气和/或撞击期间可能易于剥离。用于减少剥离趋势的一个已知特征是将从壁11延伸的阻挡肋21放置在凸缘14和褶皱裙部20之间以与装饰板10邻接。阻挡肋21优选在热焊缝的内侧边缘内延伸整个圆周。尽管肋21接触装饰板10，但是它不熔化并且不包括在焊缝中。由于他们的邻接，阻挡肋21限制充气气体抵靠热焊缝的流动，这否则至少在充气的初始阶段期间可能导致焊缝分离和失效，因为热焊缝被保护而免受可能产生剥离力的气体侵入。一旦褶皱区域17由于气囊充气而展开(即拉直)，剥离力可能继续呈现问题。例如，图5和6示出了充气的连续阶段，其中当气囊壁11和褶皱17逐渐展开时，装饰板10向外移动到乘客舱中。由于装饰板10的向外运动，剥离力23作用在凸缘14上的热焊缝上，该剥离力23仅通过热焊缝本身的粘附而抵消。
图7示出了本发明的主动垫30，其中，气囊壁31通过T形热焊缝与装饰壁32连接，这显着地增加了焊接强度(即，增加了拉开焊缝而使焊缝分离所需的力的大小)。最外侧的褶皱33具有外裙部34。双侧焊接凸缘35从裙部34一体地延伸，以便与装饰壁32的焊接轨道36热焊接。双侧焊接凸缘35具有板构件37，板构件37从裙部34(其类似于现有技术的焊接凸缘)向外径向延伸。此外，双侧焊接凸缘35包括向内的翼片38，其与焊接轨道36热焊接并且沿着装饰壁32径向向内延伸到壁31和32之间的可充气空腔39中。空腔39在撞击事件期间接收充气气体。由于其原始的注塑形状，翼片38被称为如下所述的颈部构件38。在如图7所示的最终的“热焊接”结构中，当充气气体在撞击事件期间在压力下进入空腔39时，其产生作用于颈部构件38的力40，以将颈部构件38推靠在装饰壁32上。力40抵消凸缘35从焊接凸缘35剥离的倾向。
因为模具锁定状态的可能性(即，需要具有侧向可移动元件的复杂模芯，这增加了制造成本)，具有图7所示形状的T形焊接凸缘将难以在原始注射成型部件中实现。此外，塑料热焊缝通常需要在被接合的部件的熔融表面之间进行压缩。由于位于可充气空腔内部的翼片在组件的组装过程中是不可接近的，所以在组装过程中在翼片处无法提供显著的压缩。因此，对于产生热焊缝所需的熔融表面的熔合将被削弱。
因此，本发明的优选实施例采用根据初始形状注射成型的气囊壁31，其避免了T形焊接凸缘并且不存在模具锁定。如图8所示，塑料成型的可膨胀气囊壁31具有原始的注射成型形状，其中双侧焊接凸缘35包括从(即，大体上垂直于)裙部34径向向外延伸的板构件37和大体上平行于裙部34延伸的颈部构件38。通过避免径向向内延伸，没有与气囊壁31的注射成型相关联的模具锁定状态。在注射成型过程之后，颈部构件38(其最初遵循裙部34的环形或管状形状)在热焊接过程中重新定向。优选地，颈部构件38由于与热板41的接触而径向向内偏转。当气囊壁31在箭头43的方向上与热板41接合时，热板41同时熔化凸缘35的表面并沿箭头42的方向旋转颈部构件38，更具体地说，双面热板41具有用于接触板构件37的径向表面45和用于接触颈部构件38的倾斜表面46。倾斜表面46以角度θ径向向内旋转颈部构件38。倾斜表面46从径向表面45偏离90°-θ的角度。由于颈部构件38在弯曲时被加热，所以塑料材料可以弯曲而不会开裂。由于熔融和偏转，双侧焊接凸缘35实现如图9所示的构造。为了避免板构件37在热板41弯曲颈部构件38的同时被径向向内拖动，外周唇缘47沿着板构件37的外部径向边缘设置，用作抵靠夹具(未示出)的止挡件，该夹具用于在接合热板41的同时接合板构件37。
在加热和偏转焊接凸缘35以实现图9所示的状态之后，如图10和11所示，气囊壁31与装饰壁32组装。焊接凸缘35具有部分熔融的表面层50，并且颈部构件38被定向为相对于装饰壁32的焊接轨道36倾斜。焊接轨道36可以包括肋51。此外，焊接轨道36本身可以优选地以常规方式通过与相同或不同的热板的相互作用而部分地熔化。装饰壁32优选地包括位于焊接轨道36的径向内侧的约束肋52，其将有助于在如图11所示的焊接部件的压缩期间限制颈部构件38的向内偏转(即扩展)。因此，气囊壁31和装饰壁32可以被放置在具有下部55和上部56的模具中，其中上部56向下移动到55，以便用焊接轨道36压缩板构件37。此外，成角度的放置(即不完全旋转)颈部38在颈部构件38和焊接轨道36之间产生作用力，该作用力足够使熔融层熔接成坚固的热焊缝，甚至在不能进行直接压缩的热焊缝的径向内侧。换句话说，进一步偏转颈部38直到其与板构件37平行所需的力提供了构建成功的热焊缝所需的压缩力。
图12示出了用于双侧焊接凸缘的优化尺寸。因此，板构件60具有在约3.0至约4.0mm范围内的优选厚度61。例如，厚度61可以与褶皱区域和气囊构件的主体的厚度大致相同。颈部构件62的长度63优选地在约5至约10mm的范围内，最优选地约8mm。颈部构件62的厚度64优选地在约2.0至约2.5mm的范围内。选择厚度64以优化1)在热焊接过程期间颈部构件的偏转特性，和2)形成热焊缝后而带来的结构特性。与现有技术的L形热焊接约15至20mm的径向宽度相比，板构件60的径向宽度65可以在大约12至15mm的范围内。这种减小的宽度有利地实现了增加给定面板区域的气囊尺寸的能力，因为气囊裙部的外边缘可以位于更接近热焊缝的外边缘。
要优化的另一个重要参数是热板倾斜面的倾角θ。优选地，角度θ在约25°至约45°的范围内(即，倾斜表面以大约65°至大约45°范围内的角度偏离热板的径向表面)。最优选地，颈部构件在约25至约45°的范围内的旋转为约30°。在整个组装过程中，颈部构件在两个独立的步骤中从其初始注射成型位置旋转总共约90°。具体而言，与热板接触使颈部构件旋转不大于45°的初始量，然后颈部构件在与装饰壁一起压缩期间旋转剩余量。在另一个实施例中，装饰壁可以包括用于接触颈部构件的成角度部分，并且颈部构件的所有旋转都可以在与成角度部分压缩期间发生。这也将允许焊接凸缘由热板以外的其他加热方式(例如通过IR或激光加热)来加热。
当颈部构件成形为完整的管状结构时，颈部构件的向内旋转/重新定向可能很困难，因为向内的运动减小了圆周长度。为了在弯曲操作期间避免皱褶，颈部构件70设置有如图13所示的多个释放狭槽71。狭槽71沿颈部构件70的周边设置在弯曲部分，否则在此处可能发生打褶。优选地，释放狭槽71是V形的，并且每个V形释放狭槽71的宽度适于在组装期间引起释放狭槽71的会聚，如图14和15所示。图14对应于颈部构件70的部分旋转位置(即，通过接触热板引起)，使得释放狭槽71部分地会聚。图15对应于颈部构件70在压靠在焊接轨道上之后的位置，使得释放狭槽71会聚，从而形成大体上连续的热焊缝。只要狭槽的宽度与内外径向边缘之间的弧长之差完全一致，释放狭槽71即可完全关闭。释放狭槽71不必完全关闭。
如图16所示，释放狭槽的布局也可以包括沿着颈部构件的直线部分的狭槽。因此，颈部构件75除了沿着弯曲部分的释放狭槽77之外具有沿着直线部分的多个直线狭槽76。狭槽77有助于弯曲，同时防止任何额外的皱褶。例如，宽度在2至3mm范围内的直线狭槽以大约每50mm间隔开。
图17示出了本发明的方法的一个优选实施例，其中在步骤80中，注射成型具有双侧焊接凸缘的气囊壁。在步骤81中，注射成型具有焊接轨道的装饰板。如上所述，原始成型部件具有如下构造：其中双侧焊接凸缘具有从裙部径向向外延伸的整体板构件和与裙部大体平行延伸以避免模具锁定的整体颈部构件。在步骤82中，将气囊壁的焊接凸缘与双面热板接合，以使颈部构件径向向内旋转小于90°的量。同时，热板部分地熔化焊接凸缘的接合表面。在步骤83中，装饰板壁上的焊接轨道与热板接合以便部分地熔化焊接轨道。在步骤84中，焊接凸缘和焊接轨道被压在一起(例如，在工具中)，以形成T形热焊缝。冷却后，将组件从工具中取出。

Claims (14)

1.一种用于安装在机动车辆的内部装饰表面上的主动垫，包括：
塑料成型的可膨胀的气囊壁，所述气囊壁具有终止于裙部的同心褶皱，其中所述气囊壁包括从所述裙部整体延伸的双侧焊接凸缘；和
覆盖在所述气囊壁上的塑料成型的装饰壁，其中所述双侧焊接凸缘与所述装饰壁形成热焊缝，以在撞击事件期间提供用于接收充气气体的可充气空腔；
其中所述双侧焊接凸缘包括成型为从所述裙部径向向外延伸的板构件和成型为与所述裙部大体平行地延伸的颈部构件，并且其中所述热焊缝使所述颈部构件偏转为从所述裙部径向向内延伸，使得所述颈部构件暴露于所述可充气空腔，由此来自所述充气气体的压力将所述颈部构件推靠在所述装饰壁上。
2.根据权利要求1所述的主动垫，其中，所述颈部构件被成型为包括多个释放狭槽，所述释放狭槽被构造成当针对所述热焊缝的偏转时会聚。
3.根据权利要求2所述的主动垫，其中所述释放狭槽是V形的。
4.根据权利要求1所述的主动垫，其中所述装饰壁具有位于所述热焊缝的径向内侧的突出肋，所述突出肋用于限制所述颈部构件的向内偏转。
5.根据权利要求1所述的主动垫，其中所述板构件包括沿着外径边缘的外周唇缘，所述外周唇缘用于防止所述板构件在所述焊接凸缘弯曲期间向内滑动。
6.根据权利要求1所述的主动垫，其中所述装饰壁包括结合到在所述板构件和所述颈部构件处的所述热焊缝中的多个焊接肋。
7.一种在车辆中的主动垫，包括：
具有终止于裙部的褶皱的气囊壁；和
与所述气囊壁限定空腔的装饰壁；
其中在所述装饰壁和从所述裙部整体延伸的双侧焊接凸缘之间形成T形热焊缝，其中径向向内的凸缘部分延伸到所述空腔中，使得引入所述空腔中的充气气体将所述向内部分压靠所述热焊缝。
8.一种形成用于主动垫的可充气气囊的方法，包括以下步骤：
注射成型具有终止于裙部的同心褶皱的气囊壁，其中所述气囊壁包括从所述裙部整体延伸的双侧焊接凸缘，其中所述双侧焊接凸缘包括从所述裙部径向向外延伸的板构件和与所述裙部大体上平行延伸的颈部构件；
注射成型具有焊接轨道的装饰壁；
将所述焊接凸缘与热板接合以部分熔化所述焊接凸缘的相应表面，其中所述热板具有接触所述板构件的径向表面和接触所述颈部构件的倾斜表面，所述倾斜表面用于在部分熔融期间径向向内旋转所述颈部构件；和
压缩所述焊接凸缘和所述焊接轨道以形成接合所述气囊壁和所述装饰壁的热焊缝，以形成可充气空腔。
9.根据权利要求8所述的方法，其中所述倾斜表面以约65°至约45°的范围内的角度从所述径向表面倾斜，使得所述颈部构件旋转约25°至约45°。
10.根据权利要求8所述的方法，其中所述颈部构件包括构造成由于形成所述热焊缝而会聚的多个释放狭槽。
11.根据权利要求10所述的方法，其中所述释放狭槽是V形的。
12.根据权利要求8所述的方法，其中所述装饰壁具有位于所述热焊缝的径向内侧的约束肋，所述约束肋用于在压缩步骤期间约束所述颈部构件的向内偏转。
13.根据权利要求8所述的方法，其中所述板构件包括沿着外径边缘的外周唇缘，所述外周唇缘用于防止所述板构件在所述焊接凸缘的弯曲期间向内滑动。
14.根据权利要求8所述的方法，其中所述焊接轨道包括多个焊接肋，并且其中所述方法还包括在压缩步骤之前部分地熔化所述焊接肋的步骤。
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