WO2012069912A1

WO2012069912A1 - Instrument panel module

Info

Publication number: WO2012069912A1
Application number: PCT/IB2011/002792
Authority: WO
Inventors: Yusuke Fujiwara; Osamu Fukawatase
Original assignee: Toyota Jidosha Kabushiki Kaisha
Priority date: 2010-11-26
Filing date: 2011-11-24
Publication date: 2012-05-31
Also published as: JP2012111424A

Abstract

In an instrument panel module, a decorative panel (14) that extends in a vehicle width direction so as to straddle an air bag door (24) is formed on a front side of an instrument panel substrate (12). This decorative panel (14) is fixed by welding or adhesive to a front surface (24A) of the air bag door (24) and a front surface (44A) of an adjacent portion (44) that is adjacent thereto. A pair of slits (34) that extend in the vehicle vertical direction along end portions on both sides in a vehicle width direction of the air bag door (24) are formed in the instrument panel substrate (12), and a pair of vertical grooves (50) that extend in the vehicle vertical direction along the pair of slits (34) and open on the instrument panel substrate (12) side are formed in the decorative panel (14).

Description

INSTRUMENT PANEL MODULE

BACKGROUND OF THE INVENTION 1. Field of the Invention

[0001] The invention relates to an instrument panel module.

2. Description of Related Art

[0002] Japanese Patent Application Publication No. 2008-44577 (JP-A-2008-44577), for example, describes a decorative panel that has a protruding portion and a main body portion. The protruding portion has a tip end portion and is engaged with an engaging hole formed in an instrument panel, with the tip end portion protruding from the back side of the instrument panel. The main body portion is integrally formed with this protruding portion, and is attached to the instrument panel by the protruding portion being engaged with the engaging hole.

[0003] However, when a portion of this type of decorative panel is provided on an air bag door and the tip end portion of the protruding portion that is formed on a portion of this decorative panel is protruding from the back side of the air bag door, the decorative panel may come off as a result of the air bag pushing on the tip end portion of the protruding portion when the air bag inflates and deploys.

[0004] Also, when a portion of this decorative panel is provided on an air bag door (i.e., when a portion of the decorative panel that is formed continuously in the vehicle width direction overlaps in the vehicle width direction with the air bag door, it is desirable to be able to suppress a delay in the opening of the air bag door, and thus a delay in the inflation and deployment of the air bag.

SUMMARY OF THE INVENTION

[0005] The invention thus provides an instrument panel module capable of both inhibiting a decorative panel from coming off, and suppressing a delay in the inflation and deployment of an air bag, when an air bag inflates and deploys.

[0006] A first aspect of the invention relates to an instrument panel module that includes an instrument panel substrate that has an air bag door formed so as to be able to open on at least one of a vehicle lower side and a vehicle upper side in a portion of the instrument panel substrate in front of a front passenger seat, and in which a pair of slits that extend in a vehicle vertical direction along end portions on both sides in a vehicle width direction of the air bag door are formed; an air bag unit that includes an air bag that is provided behind the air bag door, and that receives a supply of gas, pushes the air bag door open, and inflates and deploys on a front side of the instrument panel substrate; and a decorative panel of which at least a portion overlaps in the vehicle vertical direction with the pair of slits and extends in the vehicle width direction so as to straddle the air bag door and is fixed by welding or adhesive to a front surface of the air bag door and a front surface of an adjacent portion of the instrument panel substrate that is adjacent to both sides in the vehicle width direction of the air bag door, and that has a pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side.

[0007] In this instrument panel module, the air bag inflates upon receiving a supply of gas from the inflator, and as it inflates, it pushes on the air bag door. When the pressure from the air bag is transmitted to the decorative panel via the air bag door, cracks are produced in the decorative panel along the vertical grooves, and the decorative panel tears on both sides of the air bag door. Then with a portion of the decorative panel fixed to the air bag door, the air bag door opens on at least one of the vehicle lower side and the vehicle upper side, such that an opening is formed in the instrument panel substrate. The air bag then inflates and deploys on the front side of the instrument panel substrate through this opening.

[0008] Here, the decorative panel is fixed by welding or adhesive to the front surface of the air bag door and the front surface of the adjacent portion that is adjacent to both sides in the vehicle width direction of the air bag door. Therefore, it is possible to inhibit the portion of the decorative panel that is fixed to the air bag door, and both side portions thereof, from coming off when impact force when the air bag inflates and deploys is applied to the decorative panel and when the decorative panel tears on both sides of the air bag door as the air bag door opens, for example.

[0009] Also, the pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side, are formed in the decorative panel. Accordingly, when the pressure from the air bag is transmitted to the decorative panel via the air bag door, the decorative panel is able to crack along the vertical grooves, so the decorative panel is able to tear smoothly. As a result, a delay in the opening of the air bag door, and thus a delay in the inflation and deployment of the air bag, may be suppressed.

[0010] Moreover, the pair of slits extend in the vehicle vertical direction on both sides in the vehicle width direction of the air bag door. Therefore, the air bag door is able to open earlier than it would if a thin portion were formed instead of the slits, for example.

[0011] A second aspect of the invention relates to an instrument panel module that includes an instrument panel substrate that has an air bag door formed so as to be able to open on at least one of a vehicle lower side and a vehicle upper side in a portion of the instrument panel substrate in front of a front passenger seat, and in which a pair of slits that extend in a vehicle vertical direction along end portions on both sides in a vehicle width direction of the air bag door are formed; an air bag unit that includes an air bag that is provided behind the air bag door, and that receives a supply of gas, pushes the air bag door open, and inflates and deploys on a front side of the instrument panel substrate; a decorative panel of which at least a portion overlaps in the vehicle vertical direction with the pair of slits and extends in the vehicle width direction so as to straddle the air bag door and overlaps with a front surface of the air bag door and a front surface of an adjacent portion of the instrument panel substrate that is adjacent to both sides in the vehicle width direction of the air bag door, and that has a pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side; a first protruding portion that protrudes from a back surface of the decorative panel and is inserted into a first through-hole formed in the air bag door, and is retained so as not to come out of the first through-hole by a tip end portion of the first protruding portion being crimped; and a second protruding portion that protrudes from the back surface of the decorative panel and is inserted into a second through-hole formed in the adjacent portion, and is retained so as not to come out of the second through-hole by a tip end portion of the second protruding portion being crimped.

[0012] In this instrument panel module, the air bag inflates upon receiving a supply of gas from the inflator, and as it inflates, it pushes on the air bag door. When the pressure from the air bag is transmitted to the decorative panel via the air bag door, cracks are produced in the decorative panel along the vertical grooves, and the decorative panel tears on both sides of the air bag door. Then with a portion of the decorative panel fixed to the air bag door, the air bag door opens on at least one of the vehicle lower side and the vehicle upper side, such that an opening is formed in the instrument panel substrate. The air bag then inflates and deploys on the front side of the instrument panel substrate through this opening.

[0013] Here, the first protruding portion and the second, protruding portion protrude from the back surface of the decorative panel. The first protruding portion is inserted into a first through-hole formed in the air bag door, and is retained so as not to come out of the first through-hole by the tip end portion of the first protruding portion being crimped. Similarly, the second protruding portion inserted into a second through-hole formed in the adjacent portion, and is retained so as not to come out of the second through-hole by the tip end portion of the second protruding portion being crimped. Therefore, the decorative panel is fixed to the air bag door and the adjacent portion on both sides thereof. Accordingly, it is possible to inhibit the portion of the decorative panel that is fixed to the air bag door, and both side portions thereof, from coming off when impact force when the air bag inflates and deploys is applied to the decorative panel and when the decorative panel tears on both sides of the air bag door as the air bag door opens, for example.

[0014] Also, the pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side, are formed in the decorative panel. Accordingly, when pressure from the air bag is transmitted to the decorative panel via the air bag door, cracks may be produced in the decorative panel along the vertical grooves, such that a delay in the opening of the air bag door, and thus a delay in the inflation and deployment of the air bag, may be suppressed.

[0015] Moreover, the pair of slits extend in the vehicle vertical direction on both sides in the vehicle width direction of the air bag door. Therefore, the air bag door is able to open earlier than it would if a thin portion were formed instead of the slits, for example.

[0016] Here, in the instrument panel module according to the first and second aspects described above, the air bag door may be a double air bag door formed so as to be able to open on the vehicle lower side and the vehicle upper side.

[0017] Also, in the instrument panel module described above, the slits and the vertical grooves may be formed by laser machining or thermal cutting so as to form a groove with a V-shaped cross-section.

[0018] According to this instrument panel module, the slits and vertical grooves are formed simultaneously by laser machining or thermal cutting, so costs may be reduced.

[0019] Also, in the instrument panel module described above, end portions on both sides in the vehicle vertical direction of the vertical grooves may be open to end surfaces on both sides in the vehicle vertical direction of the decorative panel.

[0020] With this instrument panel module, the end portions on both sides in the vehicle vertical direction of the vertical grooves are open to the end surfaces on both sides in the vehicle vertical direction of the decorative panel. Accordingly, when pressure from the air bag is transmitted to the decorative panel via the air bag door, cracks may be produced smoothly between the end surfaces on both sides in the vehicle vertical direction of the decorative panel. As a result, the air bag door is able to open even earlier.

[0021] Also, in the instrument panel module described above, a pair of ribs that protrude from both side portions in the vehicle width direction of the vertical grooves and are inserted into the slits may be formed on a back surface of the decorative panel.

[0022] With this instrument panel module, the pair of ribs that protrude from both side portions in the vehicle width direction of the vertical grooves are formed in the back surface of the decorative panel. Accordingly, the rigidity of both side portions in the vehicle width direction of the vertical grooves is improved by the pair of ribs, so when pressure from the air bag is transmitted to the decorative panel via the air bag door, the stress may be concentrated even more at a thin portion on the bottom side of the vertical grooves. As a result, cracks may be produced more smoothly in the decorative panel along the vertical grooves.

[0023] Also, the pair of ribs are inserted into the slits, so the pair of ribs will not interfere with the instrument panel substrate.

[0024] The instrument panel module according to the second aspect may also include a door reinforcing portion that overlaps with a back surface of the air bag door and has one of a hole, a recessed portion, and a cutout portion in which the tip end portion of the first protruding portion is housed.

[0025] With this instrument panel module, the tip end portion of the first protruding portion is housed in one of a hole, a recessed portion, and a cutout portion formed in the door reinforcing portion, so the air bag is inhibited from catching on the tip end portion of the first protruding portion when the air bag deploys and inflates.

[0026] Also, in the instrument panel module described above, the air bag door may be formed in a vertically intermediate portion that is formed curved so as to be convex toward obliquely upward and backward with respect to the vehicle between an upper portion and a lower portion of the instrument panel substrate.

[0027] With this instrument panel module, the air bag deploys closer to an occupant in the front passenger seat than it does with a so-called top-mount structure in which the air bag unit is provided on an upper portion of the instrument panel substrate. As a result, restraint performance with respect to an occupant in the front passenger seat is able to be improved.

[0028] As described in detail above, the instrument panel module of the invention described above is capable of both inhibiting a decorative panel from coming off, and suppressing a delay in the inflation and deployment of an air bag, when an air bag inflates and deploys. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:

FIG 1 is a perspective view of a portion on a front passenger seat side of an instrument panel module according to a first example embodiment of the invention;

FIG. 2 is a perspective view showing a pair of air bag doors of the instrument panel module shown in FIG. 1 as they appear when open;

FIG. 3 is an enlarged sectional view taken along line III - III in FIG. 1;

FIG. 4 is an exploded view from the direction of arrow A of an instrument panel substrate and a decorative panel shown in FIG. 3;

FIG 5 is a sectional view taken along line V - V in FIG. 3;

FIG. 6 is an enlarged sectional view of a first modified example of a slit shown in FIG. 5;

FIG. 7 is an enlarged sectional view of a second modified example of a slit shown in FIG. 5;

FIG. 8 is an enlarged sectional view of a third modified example of a slit shown in FIG 5; and

FIG. 9 is a sectional view corresponding to FIG 5 of an instrument panel module according to a second example embodiment of the invention. DETAILED DESCRIPTION OF EMBODIMENTS

[0030] First, a first example embodiment of the invention will be described.

[0031] Arrows UP, FR, and RH in the drawings indicate up in the vertical direction of the vehicle (i.e., the vehicle vertical direction), the front in the longitudinal direction of the vehicle (i.e., the vehicle longitudinal direction), and the right side in the width direction of the vehicle (i.e., the vehicle width direction), respectively.

[0032] As shown in FIGS. 1 and 2, an instrument panel module 10 according to the first example embodiment of the invention includes an instrument panel substrate 12 and a decorative panel 14.

[0033] The instrument panel substrate 12 is made of resin. This instrument panel substrate 12 is arranged in a front portion of a vehicle cabin, and extends in the vehicle width direction. A vertically intermediate portion 22 that is curved to form a protrusion on the vehicle rear side and the vehicle upper side is formed between an upper portion 16 that faces up with respect to the vehicle and a lower portion 20 in which a door 18 of a glove box is provided, as shown in FIG. 3, in a portion forward of a front passenger seat, not shown, of this instrument panel substrate 12. A pair of air bag doors 24 and 26 that are lined up in the vehicle vertical direction are formed in this vertically intermediate portion 22.

[0034] Of the pair of air bag doors 24 and 26, the air bag door 24 on the vehicle lower side (hereinafter simply referred to as the "lower air bag door 24") corresponds to the air bag door of the invention. This pair of air bag doors 24 and 26 is demarcated by a pair of hinge portions 28 and 30, a designed horizontal breakaway portion 32, a pair of slits 34, and a pair of designed vertical breakaway portions 36, as shown in FIG. 4.

[0035] That is, the hinge portion 28 extends in the vehicle width direction along an end portion on the vehicle lower side of the lower air bag door 24, and the hinge portion 30 extends in the vehicle width direction along the end portion on the vehicle upper side of the air bag door 26 on the vehicle upper side (hereinafter simply referred to as the "upper air bag door 26"). The designed horizontal breakaway portion 32 extends in the vehicle width direction along the end portion on the vehicle upper side of the air bag door 24 and the end portion on the vehicle lower side of the air bag door 26.

[0036] As shown in FIG 3, a recessed portion 38 that extends in the vehicle width direction and houses a portion 54 of the decorative panel 14 that will be described later, is formed on the lower end side of a front surface 24A of the air bag door 24. Also, the hinge portion 28 is formed by a thin portion that is adjacent to the vehicle lower side of this recessed portion 38.

[0037] Meanwhile, the hinge portion 30 is formed by a thin portion that has been made thinner than the upper portion 16 and the air bag door 26 by a groove 40 having a sectional V-shape that extends in the vehicle width direction being formed in a back surface 12A of the instrument panel substrate 12. Similarly, the designed horizontal breakaway portion 32 is formed by a thin portion that has been made thinner than the pair of air bag doors 24 and 26 by a groove 42 having a sectional V-shape that extends in the vehicle width direction being formed in a back surface 12A of the instrument panel substrate 12.

[0038] As shown in FIG 4, the pair of slits 34 both extend in the vehicle vertical direction along the end portions on both sides in the vehicle width direction of the pair of air bag doors 24 and 26, and are connected the end portions on both sides in the vehicle width direction of the hinge portion 28 described above. The pair of slits 34 pass through the instrument panel substrate 12 in the thickness direction.

[0039] The pair of designed vertical breakaway portions 36 are formed on the vehicle upper side above the pair of slits 34, and extend in the vehicle vertical direction along the end portions on both sides in the vehicle width direction of the pair of air bag doors 24 and 26. Also, the pair of designed vertical breakaway portions 36 are connected to the end portions on both sides in the vehicle width direction of the hinge portion 30 and the upper end portions of the slits 34. Although not shown, the designed vertical breakaway portions 36 are formed by thin portions that that have been made thinner than the pair of air bag doors 24 and 26 by a groove having a sectional V-shape that extends in the vehicle vertical direction being formed in the back surface 12 A of the instrument panel substrate 12, just like the designed horizontal breakaway portion 32 shown in FIG 3.

[0040] Also, as shown in FIGS. 1 and 4, in the instrument panel substrate 12, a recessed portion 46 that is continuous with the recessed portion 38 and that extends in the vehicle width direction is formed in a front surface 44A of an adjacent portion 44 that is adjacent to both sides in the vehicle width direction of the air bag door 24. Also, the decorative panel 14 is housed in these recessed portions 38 and 46.

[0041] The decorative panel 14 is formed in a long shape and extends in the vehicle width direction straddling the air bag door 24. Also, this decorative panel 14 is formed narrower in the vehicle vertical direction than the air bag door 24. This decorative panel 14 is fixed by welding or adhesive to a bottom surface 38A of the recessed portion 38 that is part of the front surface 24A of the lower air bag door 24, and a bottom surface 46A of the recessed portion 46 that is part of the front surface 44A of the adjacent portion 44, while housed in the recessed portions 38 and 46.

[0042] Also, as shown in FIG 5, a pair of vertical grooves 50 that extend in the vehicle vertical direction along the slits 34 are formed in this decorative panel 14. This pair of vertical grooves 50 is formed with a V-shaped cross-section (with a tapered cross-section) that opens on the instrument panel substrate 12 side. These vertical grooves 50 are formed by laser machining or thermal cutting, together with the slits 34 described above, while the decorative panel 14 is attached to the instrument panel substrate 12. These vertical grooves 50, together with the slits 34, form grooves 52 with V-shaped cross-sections.

[0043] Also, as shown in FIG. 4, end portions 50A and 50B on both sides in the vehicle vertical direction of the vertical grooves 50 are open to end surfaces 14A and 14B on both sides in the vehicle vertical direction of the decorative panel 14. Also, when the vertical grooves 50 are formed so that the end portions 50A and 50B are open to the end surfaces 14A and 14B in this way, the pair of slits 34 formed by laser machining or thermal cutting simultaneously with these vertical grooves 50 overlap in the vehicle vertical direction with the decorative panel 14. That is, the length L of the vertical grooves 50 is substantially the same as the width W of the decorative panel 14.

[0044] Also, as shown in FIG 3, this instrument panel module 10 includes a front passenger seat air bag apparatus 60, in addition to the instrument panel substrate 12 and the decorative panel 14 described above. This front passenger seat air bag apparatus 60 is provided in the vertically intermediate portion 22. That is, this front passenger seat air bag apparatus 60 is a so-called mid-mount front passenger seat air bag apparatus. This front passenger seat air bag apparatus 60 includes a retainer 62 and an air bag unit 64.

[0045] The retainer 62 is provided on the back side of the pair of air bag doors 24 and 26, and includes a flange portion 66, a frame portion 68, and a pair of door reinforcing portions 70 and 72. The flange portion 66 is formed in a frame-shape along the outer peripheral portion of the pair of air bag doors 24 and 26, and is joined by welding, for example, to the outer peripheral portion of the pair of air bag doors 24 and 26.

[0046] This retainer 62 may be attached to the instrument panel substrate 12 before or after the decorative panel 14 is attached to the instrument panel substrate 12.

[0047] The frame portion 68 is formed in a frame-shape along the flange portion 66, and protrudes out behind the instrument panel substrate 12 from the flange portion 66. An engaging hole 74 is formed in each of a pair of side wall portions 68A of the frame portion 68 that face the vehicle vertical direction. This engaging hole 74 extends in the thickness direction of the pair of side wall portions 68A.

[0048] The pair of door reinforcing portions 70 and 72 are both formed in a plate shape and joined to the back surface of the pair of air bag doors 24 and 26, respectively, by welding for example. The door reinforcing portions 70 and 72 are connected to the flange portion 66 via hinge portions 76 and 78, respectively, that have U-shaped cross-sections.

[0049] The air bag unit 64 includes a case 80, an inflator 82, and an air bag 84. The case 80 is provided behind the pair of air bag doors 24 and 26, and is fixed to an instrument panel reinforcement 88 via a bracket 86. This case 80 is formed in a box-shape that is open on the side where the pair of air bag doors 24 and 26 are. A pair of engaging pieces 92 that extend toward the side wall portions 68A are formed on the case 80, and these engaging pieces 92 are engaged with the engaging holes 74.

[0050] The inflator 82 is a long cylindrical cylinder type inflator, and is arranged lengthwise in the vehicle width direction. Also, this inflator 82 is fixed to the bottom portion of the case 80. Upon receiving a signal output from a control unit, not shown, the inflator 82 supplies gas into the air bag 84 so that the air bag 84 will inflate and deploy.

[0051] When a frontal collision of the vehicle is actually detected or when it is predicted that a frontal collision of the vehicle will occur, the control unit, not shown, outputs a signal to the inflator 82. The air bag 84 is housed folded up inside the case 80, and a base end portion 84A of the air bag 84 is fixed to a bottom portion of the case 80.

[0052] Next, the operation and effects of the first example embodiment of the invention will be described.

[0053] In this instrument panel module 10, the air bag 84 inflates upon receiving a supply of gas from the inflator 82, and as it inflates, it pushes on the pair of air bag doors 24 and 26. When the pressure from the air bag 84 is applied to the pair of air bag doors 24 and 26, the designed horizontal breakaway portion 32 and the pair of designed vertical breakaway portions 36 shown in FIG. 1 split. Also, when the pressure from the air bag 84 (see FIG. 3) is transmitted to the decorative panel 14 via the lower air bag door 24, cracks are produced in the decorative panel 14 along the vertical grooves 50, and the decorative panel 14 tears on both sides of the air bag door 24.

[0054] Also, with a portion 54 in the center in the vehicle width direction of the decorative panel 14 fixed to the lower air bag door 24, the air bag door 24 opens downward with respect to the vehicle starting at the hinge portion 28, and the air bag door 26 opens upward with respect to the vehicle starting at the hinge portion 30. As shown in FIG. 2, an opening 94 is formed in the instrument panel substrate 12, and the air bag 84 inflates and deploys to the front side of the instrument panel substrate 12 through this opening 94. [0055] Here, the decorative panel 14 is fixed by welding or adhesive to the front surface 24 A of the air bag door 24 and the front surface 44 A of the adjacent portion 44 that is adjacent thereto. Therefore, it is possible to inhibit the portion 54 of the decorative panel 14 that is fixed to the air bag door 24, and both side portions 56 thereof, from coming off when impact force when the air bag inflates and deploys is applied to the decorative panel 14 and when the decorative panel 14 tears on both sides of the lower air bag door 24 as the air bag door 24 opens, for example.

[0056] Also, a protruding portion for engagement that passes through the air bag door 24 does not need to be provided on the decorative panel 14, so the air bag 84 is inhibited from getting caught when it deploys and inflates.

[0057] Also, as shown in FIG 1, the pair of vertical grooves 50 with the V-shaped cross-sections that extend in the vehicle vertical direction along the slits 34 and are open on the instrument panel substrate 12 side are formed in the decorative panel 14. Accordingly, when the pressure from the air bag 84 is transmitted to the decorative panel 14 via the air bag door 24, cracks are able to be produced in the decorative panel 14 along the vertical grooves 50, so the decorative panel 14 is able to tear smoothly. As a result, a delay in the opening of the air bag door 24, and thus a delay in the inflation and deployment of the air bag 84, may be suppressed.

[0058] Moreover, the pair of slits 34 are formed in the vehicle vertical direction on both sides in the vehicle width direction of the air bag door 24. Therefore, the air bag door 24 is able to open earlier than it would if a thin portion were formed instead of the slits 34, for example.

[0059] Also, as shown in FIG. 4, the end portions 50A and 50B on both sides in the vehicle vertical direction of the vertical grooves 50 are open to the end surfaces 14A and 14B on both sides in the vehicle vertical direction of the decorative panel 14. Therefore, when pressure from the air bag 84 is transmitted to the decorative panel 14 via the lower air bag door 24, cracks are able to be smoothly produced between the end surfaces 50A and 50B of the decorative panel 14. As a result, the air bag door 24 is able to open even earlier. [0060] Also, the slits 34 and the vertical grooves 50 are formed simultaneously by laser machining or thermal cutting, so costs may be reduced.

[0061] Further, the vertical grooves 50 are formed by laser machining or thermal cutting after the decorative panel 14 has been attached to the instrument panel substrate 12, so folds or bends or the like that may occur in the decorative panel 14 when the decorative panel 14 is being attached may be suppressed.

[0062] Also, the decorative panel 14 overlaps with the pair of slits 34 in the vehicle vertical direction, so the pair of slits 34 are covered by the decorative panel 14, which makes it possible to ensure that a good appearance of the instrument panel substrate 12.

[0063] Moreover, even if the portion 54 of the decorative panel 14 is provided on the air bag door 24, the air bag door 24 is able to open reliably, as described above. Accordingly, it is possible to avoid the arrangement of the decorative panel 14 from being restricted, so the degree of freedom with respect to the arrangement of the decorative panel 14 may be improved.

[0064] Next, a modified example of the first example embodiment of the invention will be described.

[0065] In the first example embodiment of the invention, the slits 34 and the vertical grooves 50 are simultaneously formed by laser machining or thermal cutting, but the slits 34 may also be formed when injection molding the instrument panel substrate 12, and only the vertical grooves 50 may be formed by laser machining or thermal cutting after the decorative panel 14 has been attached to the instrument panel substrate 12.

[0066] Also, in this case, the slits 34 may be formed with substantially the same width as the openings of the vertical grooves 50, as shown in FIG. 6, or may be formed wider than the openings of the vertical grooves 50, as shown in FIG. 7.

[0067] Further, if the slits 34 are formed wider than the openings of the vertical grooves 50, a pair of ribs 96 that protrude from both side portions in the vehicle width direction of the vertical grooves 50 and are inserted into the slits 34 may be formed on the back surface 14C of the decorative panel 14, as shown in FIG 8. [0068] With this kind of structure, the rigidity of both side portions in the vehicle width direction of the vertical grooves 50 is improved by the pair of ribs 96, so when pressure from the air bag 84 (see FIG 3) is transmitted to the decorative panel 14 via the air bag door 24, stress may be concentrated even more at a thin portion 98 on the bottom side of the vertical grooves 50. As a result, cracks may be produced more smoothly in the decorative panel 14 along the vertical grooves 50.

[0069] Also, the pair of ribs 96 are inserted into the slits 34, so the pair of ribs 96 will not interfere with the instrument panel substrate 12.

[0070] The instrument panel substrate 12 and the decorative panel 14 may be positioned by the pair of ribs 96 being inserted into the slits 34.

[0071] Also, as shown in FIG 4, the end portions 50A and 50B on both sides in the vehicle vertical direction of the vertical grooves 50 are open to the end surfaces 14A and 14B on both sides in the vehicle vertical direction of the decorative panel 14, but if the air bag door 24 is able to open smoothly, for example, the end portions 50A and 50B may also be terminate just before the end surfaces 14A and 14B. In this case, the slits 34 that are formed simultaneously with the vertical grooves 50 by laser machining or thermal cutting overlap a portion of the decorative panel 14 between the end surfaces 14 A and 14B in the vehicle vertical direction.

[0072] Also, as shown in FIG. 3, the front passenger seat air bag apparatus 60 is a mid-mount front passenger seat air bag apparatus that is provided on the vertically intermediate portion 22 of the instrument panel substrate 12, but it may also be a top-mount front passenger seat air bag apparatus that is provided on the upper portion 16 of the instrument panel substrate 12, for example.

[0073] Further, the decorative panel 14 is provided straddling the lower air bag door 24 as shown in FIG. 1, but it may also be provided straddling the upper air bag door 26. In this case, the pair of slits 34 are formed along the end portions on both sides in the vehicle width direction of the upper air bag door 26. In this case, of the pair of air bag doors 24 and 26, the upper air bag door 26 corresponds to the air bag door of the invention. [0074] Next, a second example embodiment of the invention will be described.

[0075] An instrument panel module 100 according to the second example embodiment of the invention that is shown in FIG 9 is modified in structure from the instrument panel module 10 (see FIGS. 1 to 5) according to the first example embodiment of the invention described above.

[0076] That is, the decorative panel 14 overlaps with the bottom surface 38A of the recessed portion 38 and the bottom surface 46A of the recessed portion 46 when housed in the recessed portions 38 and 46. Also, a first protruding portion 102 and a second protruding portion 104 protrude from the back surface 14C of the decorative panel 14. The first protruding portion 102 is inserted into a first through-hole 106 formed in the air bag door 24, and the second protruding portion 104 is inserted into a second through-hole 108 formed in the adjacent portion 44.

[0077] Also, a tip end portion 102A of the first protruding portion 102 is engaged with a peripheral edge portion of the first through-hole 106 by crimping, and is thus prevented from coming out of the first through-hole 106. Similarly, a tip end portion 104 A of the second protruding portion 104 is engaged with a peripheral edge portion of the second through-hole 108 by crimping, and is thus prevented from coming out of the second through-hole 108.

[0078] Also, a hole 110 is formed in the door reinforcing portion 70 that overlaps with a back surface 24B of the air bag door 24. This hole 110 is formed in the thickness direction of a door reinforcing portion 70. A tip end portion 102A of the first protruding portion 102 is housed in this hole 110. The depth of this hole 110 is greater than the height of the tip end portion 102A after crimping.

[0079] Next, the differences in the operation and effect of this second example embodiment of the invention from the first example embodiment of the invention described above will now be described.

[0080] That is, with this instrument panel module 100, the decorative panel 14 is fixed to the air bag door 24 and the adjacent portion 44 on both sides thereof, by the first protruding portion 102 being retained so as not to come out of the first through-hole 106, and the second protruding portion 104 being retained so as not to come out of the second through-hole 108. It is thus possible to inhibit the portion 54 of the decorative panel 14 that is fixed to the air bag door 24, and both side portions 56 thereof, from coming off when impact force when an air bag 84 inflates and deploys is applied to the decorative panel 14 and when the decorative panel 14 tears on both sides of the air bag door 24 as the air bag door 24 opens, for example.

[0081] Also, the tip end portion 102A of the first protruding portion 102 is housed in the hole 110 formed in the door reinforcing portion 70. As a result, the air bag 84 may be inhibited from catching on the tip end portion 102A of the first protruding portion 102 when the air bag 84 deploys and inflates.

[0082] Although not particularly shown, the first through-hole 106 may be formed through the air bag door 24 and the door reinforcing portion 70, and the tip end portion 102 A of the first protruding portion 102 may be engaged with the peripheral edge portion of this first through-hole 106 by being crimped. In this case, the tip end portion 102 A is crushed as a result of being crimped, so the air bag 84 is inhibited from catching on the tip end portion 102 A.

[0083] Also, the hole 110 is formed in the door reinforcing portion 70 so as to pass through the heat exchanger 70 in the thickness direction. However, instead of this hole 110, a recessed portion that opens on the air bag door 24 side, or a cutout portion that has been cut away from the side surface of the door reinforcing portion 70 may be formed, and the tip end portion 102 A of the first protruding portion 102 may be housed in this recessed portion or cutout portion.

[0084] Also, the second example embodiment of the invention may also be modified like to modified example of the first example embodiment of the invention described above.

[0085] While example embodiments of the invention have been described, the invention is not limited to these example embodiments. That is, the invention may of course be embodied with various changes, modifications or improvements, without departing from the spirit and scope of the invention.

Claims

CLAIMS:

1. An instrument panel module comprising:

an instrument panel substrate that has an air bag door formed so as to be able to open on at least one of a vehicle lower side and a vehicle upper side in a portion of the instrument panel substrate in front of a front passenger seat, and in which a pair of slits that extend in a vehicle vertical direction along end portions on both sides in a vehicle width direction of the air bag door are formed;

an air bag unit that includes an air bag that is provided behind the air bag door, and that receives a supply of gas, pushes the air bag door open, and inflates and deploys on a front side of the instrument panel substrate; and

a decorative panel of which at least a portion overlaps in the vehicle vertical direction with the pair of slits and extends in the vehicle width direction so as to straddle the air bag door and is fixed by welding or adhesive to a front surface of the air bag door and a front surface of an adjacent portion of the instrument panel substrate that is adjacent to both sides in the vehicle width direction of the air bag door, and that has a pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side.

2. An instrument panel module comprising:

an air bag unit that includes an air bag that is provided behind the air bag door, and that receives a supply of gas, pushes the air bag door open, and inflates and deploys on a front side of the instrument panel substrate; a decorative panel of which at least a portion overlaps in the vehicle vertical direction with the pair of slits and extends in the vehicle width direction so as to straddle the air bag door and overlaps with a front surface of the air bag door and a front surface of an adjacent portion of the instrument panel substrate that is adjacent to both sides in the vehicle width direction of the air bag door, and that has a pair of vertical grooves, each of which has a V-shaped cross-section and extends in the vehicle vertical direction along a corresponding slit from among the pair of slits and opens on the instrument panel substrate side;

a first protruding portion that protrudes from a back surface of the decorative panel and is inserted into a first through-hole formed in the air bag door, and is retained so as not to come out of the first through-hole by a tip end portion of the first protruding portion being crimped; and

a second protruding portion that protrudes from the back surface of the decorative panel and is inserted into a second through-hole formed in the adjacent portion, and is retained so as not to come out of the second through-hole by a tip end portion of the second protruding portion being crimped.

3. The instrument panel module according to claim 1 or 2, wherein the air bag door is a double air bag door formed so as to be able to open on the vehicle lower side and the vehicle upper side.

4. The instrument panel module according to any one of claims 1 to 3, wherein the slits and the vertical grooves are formed by laser machining or thermal cutting so as to form a groove with a V-shaped cross-section.

5. The instrument panel module according to any one of claims 1 to 4, wherein end portions on both sides in the vehicle vertical direction of the vertical grooves are open to end surfaces on both sides in the vehicle vertical direction of the decorative panel.

6. The instrument panel module according to any one of claims 1 to 5, wherein a pair of ribs that protrude from both side portions in the vehicle width direction of the vertical grooves and are inserted into the slits are formed on a back surface of the decorative panel.

7. The instrument panel module according to claim 2, further comprising a door reinforcing portion that overlaps with a back surface of the air bag door and has one of a hole, a recessed portion, and a cutout portion in which the tip end portion of the first protruding portion is housed.

8. The instrument panel module according to any one of claims 1 to 7, wherein the air bag door is formed in a vertically intermediate portion that is formed curved so as to be convex toward obliquely upward and backward with respect to the vehicle between an upper portion and a lower portion of the instrument panel substrate.