WO2023147086A2 - Component for vehicle interior - Google Patents

Component for vehicle interior Download PDF

Info

Publication number
WO2023147086A2
WO2023147086A2 PCT/US2023/011784 US2023011784W WO2023147086A2 WO 2023147086 A2 WO2023147086 A2 WO 2023147086A2 US 2023011784 W US2023011784 W US 2023011784W WO 2023147086 A2 WO2023147086 A2 WO 2023147086A2
Authority
WO
WIPO (PCT)
Prior art keywords
component
connector
airbag
segment
base panel
Prior art date
Application number
PCT/US2023/011784
Other languages
French (fr)
Other versions
WO2023147086A3 (en
Inventor
Martin Lippert
Andreas Luedtke
Lucas STEFFENS
Original Assignee
Yanfeng International Automotive Technology Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Yanfeng International Automotive Technology Co., Ltd. filed Critical Yanfeng International Automotive Technology Co., Ltd.
Publication of WO2023147086A2 publication Critical patent/WO2023147086A2/en
Publication of WO2023147086A3 publication Critical patent/WO2023147086A3/en

Links

Classifications

    • 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
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • 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
    • B60R21/215—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components characterised by the covers for the inflatable member
    • B60R21/2165—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components characterised by the covers for the inflatable member characterised by a tear line for defining a deployment opening
    • 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
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • 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
    • B60R21/215—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components characterised by the covers for the inflatable member
    • B60R2021/21537—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components characterised by the covers for the inflatable member characterised by hinges

Definitions

  • the present invention relates to a component for a vehicle interior.
  • the present invention also relates to component for a vehicle interior configured to facilitate deployment of an airbag into the vehicle interior.
  • an improved component for a vehicle interior comprising a base panel providing a separation area with a set of segments comprising a connector and/or feature configured to form a door for deployment of the airbag into the interior.
  • an improved component for a vehicle interior comprising a base panel providing a separation area with a set of segments comprising a connector and/or feature configured to direct a stress concentration to provide a rupture of the base panel to form a door for deployment of the airbag into the interior.
  • the present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag
  • a base comprising a base panel with a separation area.
  • the base may be configured to form a door at the separation area of the base panel to provide an opening for deployment of the airbag through the base panel.
  • the separation area may comprise a set of segments. Each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. Each segment may comprise features configured to selectively locate a stress concentration for rupture at the separation area during deployment.
  • the base may be configured to form the door along the separation area of the base panel to provide the opening for deployment of the airbag through the base panel.
  • the separation area may be configured to define the opening for deployment of the airbag.
  • the separation area may be configured to define a shape of the opening for deployment of the airbag.
  • the separation area may be configured to define a shape of a flap for the door for deployment of the airbag.
  • the separation area may comprise a separation line.
  • the separation line may comprise a seam.
  • the separation line may comprise a tear line.
  • Each segment may comprise a connector between the door and the base panel.
  • Each connector may comprise a connection section.
  • Each connector may comprise a separation section.
  • the separation section may comprise a rupture area.
  • Each connector may comprise a rupture section.
  • Each connector may comprise a bridge section.
  • Each connector may comprise a web section.
  • Each connector may comprise a web of material.
  • Each connector may comprise a bridge comprising a web of material.
  • Each connector may comprise a profile. Each connector may comprise a shape. Each connector may comprise a section. Each segment may comprise a feature. The feature may comprise a feature on the connector. Each segment may comprise the connector and a feature. The feature may comprise a feature located adjacent to the connector. The feature at the segment may be configured to facilitate rupture of the connector at a rupture area of the segment.
  • the feature at the segment may comprise at least one of a gap, groove, countergroove, tapering, multidimensional tapering, notch, counternotch, opening, aperture, cavity, rib, profile, shape, variation of width.
  • the feature at the segment may comprise at least one of a gap and/or a groove and/or an opening.
  • the feature at the segment may comprise at least one of a groove and/or a countergroove and/or a rib.
  • the feature at the segment may comprise at least one of tapering of the connector and/or multi-dimensional tapering of the connector and/or variation of width of the connector and/or variation of height of the connector.
  • the feature at the segment may comprise tapering of the connector.
  • the feature at the segment may comprise multi-dimensional tapering of the connector.
  • the feature at the segment may comprise variation of width and/or height of the connector.
  • the feature at the segment may comprise at least one of variation of thickness of the connector and/or variation of shape of the connector.
  • the feature at the segment may comprise at least one of a notch and/or a countemotch.
  • the feature at the segment may be configured to direct a stress concentration to a rupture area of the connector.
  • the stress concentration may be sufficient to separate the door from the base panel at the rupture area.
  • the stress concentration may be sufficient to rupture the seam of the base panel to form the door at the rupture area.
  • the connection area may be provided between the base panel and the door.
  • the connector may comprise a trapezoidal shape.
  • the connector may comprise a tapering shape.
  • the connector may comprise a tapering profile.
  • the connector may comprise a curved profile.
  • the connector may comprise a sloped profile.
  • the connector may comprise a thin section at the separation area at the base panel.
  • the separation area of the base panel may be configured to comprise a relatively smooth separation surface after deployment of the airbag door.
  • the separation area may be configured to comprise a relatively smooth rupture area.
  • each segment may comprise a section comprising a gap and a section comprising a connector.
  • the connector may comprise a trapezoidal shape and the gap may comprise an aperture in the base panel adjacent the connector.
  • the aperture may comprise a shape comprising a middle portion between a first leg and a second leg. A height of the trapezoidal shape of the connector may be greater than a width of the middle portion of the aperture.
  • the aperture may comprise an obtuse angle between the first leg and the middle portion.
  • the first leg may comprise a length greater than a width of the middle portion.
  • the aperture may comprise a concave polygon shape.
  • the concave polygon shape may comprise more than six sides.
  • Each section may comprise a gap of a first distance and a section comprising a gap of a second distance and a connector comprising a tapering profile.
  • Each segment may comprise a bracket- shaped gap.
  • Each segment may comprise (a) a generally ]- shaped gap; (b) a generally ⁇ _/ shaped gap; or (c) a generally U shaped gap.
  • Each segment may comprise a notch.
  • Each connector may comprise a tapered bridge.
  • Each connector may comprise a recess.
  • the connector may comprise a curved profile.
  • the connector may comprise a parabolic profile.
  • the connector may comprise a notch adjacent the separation area.
  • the connector may comprise a curve body.
  • the connector may comprise a thin section at the separation area.
  • the thin section may comprise a stress concentration sufficient to provide rupture at deployment of the airbag.
  • Each segment may be configured to form a separation surface at the opening in the base panel.
  • Each segment may be configured to form a projection at the airbag door.
  • the connector may comprise a varying size along the separation area.
  • the connector may comprise a varying profile along the separation area.
  • the connector may comprise a multi-dimensional profile.
  • Each segment may comprise a varying profile along the separation area.
  • Form of feature may vary along the separation area. Depth of the feature may vary along the separation area.
  • the rib may comprise a continuous rib around the airbag door.
  • the rib may be at the separation area.
  • the rib may comprise a stiffening rib.
  • the feature may comprise a slot.
  • the slot may comprise a bracketshaped slot.
  • the connection area may be configured to develop a stress concentration during deployment of the airbag.
  • the stress concentration may be configured to establish a rupture area in the connection area.
  • the connector may be configured to rupture at the rupture area at deployment of the airbag.
  • the connector may comprise a profile configured to facilitate rupture of the connector at the rupture area of the segment.
  • the rupture may be at a designated area of the connector.
  • the seam may comprise a line.
  • the set of segments may be provided along the line.
  • the line may comprise a tear line.
  • the rupture may be at the seam.
  • the rupture may be at the tear line.
  • the connector may be configured to form a projection at deployment of the airbag.
  • the projection may comprise a tab.
  • the projection may be formed on the door.
  • Each segment may be configured to form a generally uniform tab on the door at deployment of the airbag.
  • the generally uniform tab of each segment may comprise a projection having substantially the same form at each segment.
  • the generally uniform tab of each segment may comprise a projection having substantially the same size at each segment.
  • the generally uniform tab of each segment may comprise a projection having substantially the same shape at each segment.
  • the panel may comprise a structural substrate.
  • the structural substrate may comprise a molded substrate.
  • the molded substrate may comprise an injection molded substrate.
  • the base panel with the seam and the door may be integrally formed.
  • the base panel with the seam and the door may be injection molded.
  • the structural substrate may be formed in an apparatus.
  • the base panel may be formed in an apparatus.
  • the apparatus may comprise a mold.
  • Each segment may be formed in the base panel by a tool.
  • the tool may comprise a slider arrangement.
  • the slider arrangement may be configured to form the seam in the base panel.
  • the slider arrangement may comprise a slider configured to form a connector at each segment.
  • the slider arrangement of the apparatus may be configured to form a feature at each segment.
  • the seam may comprise a weakening line.
  • the seam may comprise a tear line.
  • the structural substrate may be formed by a method.
  • the base panel may be formed by a method.
  • the method may comprise the steps of (a) forming the base panel and (b) forming a seam in the base panel to provide the door.
  • the seam may be formed by a tool.
  • the tool may comprise a slider arrangement.
  • the step of forming the seam in the base panel may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a connector at each segment.
  • the step of forming the set of segments in the base panel may comprise forming a feature at each segment.
  • the step of forming the base panel may comprise injection molding a resin material to form the base panel.
  • the component may comprise a hinge coupling the door to the base panel at deployment of the airbag.
  • the hinge may comprise reinforcement.
  • the reinforcement may comprise fabric.
  • the set of segments may be configured to form a weakening line at the seam of the base panel.
  • the seam may comprise a weakening line in the base panel.
  • the seam may comprise a weakening area.
  • the seam may comprise a tear area.
  • the seam may comprise a separating area.
  • the seam may comprise a weakening area between the door and the base panel.
  • Each segment may comprise a connector comprising a connecting material.
  • the base may comprise a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of cavities in the rear side of the structural substrate.
  • the set of cavities may comprise at least one cavity comprising a profile. Each segment may comprise a cavity.
  • the present invention relates to a method of producing a component configured for deployment of an airbag comprising the steps of forming a base panel; and forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag.
  • the seam may be formed by a tool.
  • the step of forming the separation area in the base panel may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a connector at each segment.
  • the tool may comprise a slider arrangement.
  • the step of forming the separation area may comprise forming a seam in the base panel.
  • the step of forming the seam may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a feature at each segment.
  • the step of forming the set of segments in the base panel may comprise forming a connector comprising a feature at each segment.
  • the step of forming the base panel may comprise injection molding a resin material to form the base panel.
  • the door may comprise an airbag door with a hinge provided in the base panel.
  • the present invention relates to an apparatus for producing a component configured for deployment of an airbag
  • a mold configured for forming a base panel and a tool configured for forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag.
  • the tool may comprise a slider arrangement.
  • the separation area may comprise a seam.
  • the seam may comprise a set of segments.
  • the slider arrangement may comprise a set of slider elements.
  • the slider elements may comprise a set of blades.
  • the slider elements may comprise elements of varying size and/or varying depth.
  • the slider elements may comprise elements of varying shape.
  • the slider elements may comprise elements of varying form.
  • the mold may comprise an injection mold; the mold may be configured to form the base panel from injection-molded resin.
  • the tool may be configured to form a set of segments for the seam.
  • Each segment may comprise a feature.
  • the feature may comprise a connector.
  • the feature may comprise a gap.
  • the present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag
  • a structural substrate comprising a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a separation area for the opening for deployment of the airbag.
  • the line may comprise a set of segments in the structural substrate. Each segment of the set of segments may comprise a feature.
  • the feature may be configured to facilitate formation of an opening in the structural substrate at the line for deployment of the airbag.
  • the line may comprise a tear line.
  • the line may comprise a separation line in the separation area.
  • the separation area may comprise a separation line.
  • the separation line may comprise a tear line.
  • Each segment of the set of segments may comprise a connector.
  • the connector may comprise a profile.
  • the feature may comprise the connector.
  • the feature may comprise a cavity.
  • the cavity may be formed in the rear side of the structural substrate.
  • the cavity may comprise a profile.
  • the structural substrate may comprise a base comprising a base panel.
  • the line may comprise a seam. At deployment of the airbag the base may be configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel.
  • the seam may comprise the set of segments.
  • Each segment may comprise a connector of the door to the base panel.
  • the connector of each segment may be configured to separate to facilitate formation of the opening.
  • the feature may comprise the connector.
  • the front side of the panel may comprise a contoured surface.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the feature may comprise a notch.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate.
  • the profile of the cavity may comprise a depth within the rear side of the structural substrate.
  • the profile of the cavity may comprise a curved surface.
  • the profile of the cavity may comprise a flat surface.
  • the profile of the cavity may comprise a curved shape.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • the present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a separation area for the opening for deployment of the airbag.
  • the separation area may comprise a set of gaps in the structural substrate.
  • the set of gaps may comprise at least one gap comprising a profile.
  • the separation area may comprise a line.
  • the separation area may comprise a separation line.
  • the separation line may comprise a tear line.
  • the separation line may comprise a seam.
  • the line may comprise a seam comprising a set of features.
  • the set of features may comprise a set of connectors.
  • the set of features may comprise the set of gaps and the set of connectors.
  • the profile of the connector may comprise a curved surface.
  • the profile of the connector may comprise a flat surface.
  • the profile of the connector may comprise a tapered shape.
  • the profile of the connector may comprise a curved shape.
  • the seam may comprise the tear line.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate.
  • the profile of the gap may comprise a curved surface.
  • the profile of the gap may comprise a flat surface.
  • the profile of the gap may comprise a curved shape.
  • the gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side.
  • the opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • the present invention relates to an airbag system for an interior of a vehicle configured for deployment of an airbag for an occupant of the vehicle upon an event comprising (a) an airbag module providing the airbag configured for deployment from the component; and (b) a base of the component comprising a base panel with a seam.
  • the base may be configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel.
  • the seam may comprise a set of segments. Each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. Each segment may comprise a feature configured to facilitate formation of the opening for deployment of the airbag.
  • the present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of cavities in the rear side of the structural substrate.
  • the set of cavities may comprise at least one cavity comprising a profile.
  • the front side of the panel may comprise a substantially planar surface opposite the at least one cavity.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate.
  • the profile of the cavity may comprise a depth within the rear side of the structural substrate.
  • the profile of the cavity may comprise a curved surface.
  • the profile of the cavity may comprise a flat surface.
  • the profile of the cavity may comprise a curved shape.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • the present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of gaps in the structural substrate.
  • the set of gaps may comprise at least one gap comprising a profile.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate.
  • the profile of the gap may comprise a curved surface.
  • the profile of the gap may comprise a flat surface.
  • the profile of the gap may comprise a curved shape.
  • the gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side.
  • the opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.
  • FIGURE IB is schematic partial perspective view of a vehicle interior according to an exemplary embodiment.
  • FIGURES 2A and 2B are schematic partial perspective views of a vehicle interior according to an exemplary embodiment.
  • FIGURE 3A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.
  • FIGURES 3B through 3D are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.
  • FIGURES 4A through 4F are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.
  • FIGURE 5A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 5B is schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 5C is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 6A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 6B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 6C is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 6D is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 6E is schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7B is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7C is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7D is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7E is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7F is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 7G is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 8A through 8C are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 9A through 9C are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 10A through 10F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 11 A through 1 IF are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 12A through 12F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 13A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 13B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 13C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 13D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 13E and 13F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 13G and 13H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 14A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 14B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 14C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 14D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 14E and 14F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 14G and 14H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 15A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 15B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 15C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 15D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 15E and 15F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 15G and 15H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 16A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 16B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 16C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 16D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 16E and 16F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 16G and 16H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 17A through 17D are schematic cutaway perspective views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 18A and 18B are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 19 is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 20 is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 21 A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 21B is a schematic cutaway section perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 21C is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 21D is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22A is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22B is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22C is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22D is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22E is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 22F is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23B is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23C is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23D is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23E is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 23F is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24B is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24C is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24D is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24E is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 24F is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 25 is a schematic exploded perspective view of a tool/apparatus configured to a produce a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 26A through 26D are schematic section views of a tool/apparatus configured to a produce a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 27A through 27D are schematic perspective views of a tool configured to a produce a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 27E is schematic cutaway perspective view of a tool configured to a produce a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 28 A through 28C are schematic section views of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 28D is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 29A through 29C are schematic section views of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 29D is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 30 is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 31 A is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 3 IB is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURE 31C is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
  • FIGURES 32A and 32B are schematic partial section views of a segment of a panel of a component for a vehicle interior indicating a stress concentration under load of deployment of an airbag through the panel of the component according to an exemplary embodiment.
  • a vehicle V is shown with an interior I comprising components C such as an instrument panel IP, door panel DP, steering wheel SW, seats ST, and other trim panels/components.
  • components C such as an instrument panel IP, door panel DP, steering wheel SW, seats ST, and other trim panels/components.
  • the components of the interior of the vehicle may be configured for deployment of an airbag AB such as from an airbag assembly/module ABM through an opening formed by a door ABD at a separation area shown as weakening/tear line TR in the component shown as instrument panel C/IP (e.g. deployment of airbag upon detection of an event).
  • an airbag AB such as from an airbag assembly/module ABM through an opening formed by a door ABD at a separation area shown as weakening/tear line TR in the component shown as instrument panel C/IP (e.g. deployment of airbag upon detection of an event).
  • the component such as instrument panel C/IP may comprise a base panel BP shown as comprising a structural substrate SB and an intermediate layer shown as a foam layer FM and a cover shown as cover layer TX; the component C with base panel BP may be configured for an installation of an airbag system/assembly such as within housing HN (e.g. assembled to the component) for deployment of an airbag AB through an opening formed by the airbag door ABD at the separation area/line TR upon actuation of an inflator NF. See also FIGURES 4A-4F (deployment of airbag from airbag system/module through door/opening formed in base panel of component).
  • the intermediate layer may comprise any of a variety of materials such as a foam material/layer, spacer, fabric, soft layer, functional layer, sensor layer, haptic layer, other material/layer/combination, etc.);
  • the cover layer may be any of a variety of materials including fabric, leather, synthetic leather, plastic/polymer materials, films, etc. See also FIGURES 23A-23F and 24A-24F.
  • the component C may comprise the base panel BP with a separation area/line SP/TR comprising a set of segments SG configured for formation of the airbag door ABD at deployment of the airbag AB; each segment SG of the set of segments may comprise a connector CN shown as a bridge (e.g.
  • each segment of the set of segments may comprise a feature such as a profile/shape FP for connector CN and a gap FG at or adjacent to connector CN and/or a notch FN at or adjacent to connector CN and/or other feature within the segment SG. See also FIGURES 9A-9C.
  • the airbag door ABD will be formed in the base panel BP at and along the separation area/line TR provided by the set of segments SG; a rupture RR will form at the connector CN at each segment SG and airbag door ABD will separate from base panel BP. See also FIGURES 4A-4F.
  • a separation is intended to develop at or adjacent to a feature such as gap FG and/or profile FP of connector CN; as indicated schematically, relative position/relationship and type/shape and form/profile of the connector and/or the feature of the segment will direct a stress concentration to a separation area SP/TR at the segment to form a rupture area RP and rupture RR to facilitate formation of the opening and airbag door ABD along the separation area/line SP.
  • the combination/relationship of the feature and the connector CN such as the configuration of the gap FG or the presence of a notch FN or the shape/profile of the connector CN such as taper FT may be arranged to facilitate location of the separation area SP/rupture area RP for rupture RR at an intended position at the segment SG and/or on the connector CN. See also FIGURES 21A-21D and 22A-22F.
  • the segments SG of the separation area SP/TR can be configured with a connector CN and features such as profile FP and/or notch FN in an arrangement intended to provide a selectively-located rupture area RP at deployment of the airbag AB (e.g. as without projections into the opening in the base panel for airbag deployment) and/or a more generally uniform shape/form of projections CN/PR from the airbag door (e.g. without substantial residual on the base panel, with substantial entirety of body on the airbag door, with less chipping/fragmentation, etc.). See also FIGURES 21A- 21D and 22A-22F.
  • the separation of the airbag door ABD from the base panel BP at the separation area SP/TR will produce a separation surface SF on the base panel BP and a projection CN/PR on the airbag door ABD.
  • FIGURES 8A-8C and 9A-9C separation at a tear line TR within a segment SG may produce an irregular shape/form of surfaces SF and/or projections CN/PR at each side of the separation (including at the base panel as may project into the opening for the airbag deployment); such irregularities such as from projections or surfaces at the tear line may contact and damage /affect or impede the deployment of the airbag (e.g.
  • separation at a tear line TR within a segment SG with a connector CN and a gap FG may produce a generally uniform and/or regular shape/form and position/placement of surfaces SF and or projections CN/PR on the airbag door ABD; such general uniformity such as from projections CN/PR on the airbag door and uniform surfaces SF at the tear line may reduce the potential for contact as would impede deployment or may damage the airbag (e.g.
  • the form/location of the gap FG in relation to the location/profile FP of the connector CN may be configured and/or combined to provide a set or surfaces SF along the base panel BP that do not extend into the opening for the airbag (e.g. within the separation line TR and within surfaces forming gap FG). See also FIGURES 7B-7F and 17A-17D.
  • the airbag door ABD may comprise a feature such as a rib FR and/or other rigidifying material (such as a grid/web, frame, border, etc.) and/or a reinforcement such as a fabric sheet for a hinge HG at the attachment to the base panel BP.
  • the airbag door ABD may be formed with a generally uniform door without a rib/member.
  • the segments SG of the separation area SP can be configured with a connector CN and features such as profile FP or notch FN in an arrangement intended to provide a selectively-located rupture area RP at deployment of the airbag AB (e.g. as without projections into the opening in the base panel for airbag deployment) and/or a more generally uniform shape/form of projections CN/PR from the airbag door (e.g. without substantial residual on the base panel, with substantial entirety of body on the airbag door, with less chipping/fragmentation, etc.). See also FIGURES 7A-7F, 9A-9C and 17A-17D.
  • each segment SG of the separation area/line SP/TR with connector CN with profile FP shown as curved profile/shape
  • adjacent features such as rib FR and notch FN and etc.
  • RC directed/localized stress concentration
  • FIGURES 32A-32B As indicated in FIGURES 7A-7F, 10A-10F, 18A-18B, 19 and 20, the segments SG of the separation area for the airbag door ABD of base panel BP may be sized/shaped and configured in a variety of arrangements to facilitate the deployment of an airbag for the component.
  • a stress concentration RC may be produced at a segment of the separation line of a panel of a component under load of deployment of an airbag through the panel of the component; as indicated schematically, stress concentration RC-1 is a sufficient stress concentration as may produce a rupture at the location of the stress concentration (stress concentration RC-2 and RC-3 are progressively lower stress concentrations); configuration of the segment with form/profile and shape/size of the connector and feature may be arranged to direct the stress concentration within the segment to produce separation/rupture at or within an intended region. See also FIGURES 7A-7F and 9A-9C.
  • the component may be formed from a process as with a substrate SB such as a structural substrate that is injection molded from a resin/polymer NP in a tool as a formed substrate with the separation area formed; an intermediate layer such as a foam layer FM is applied to the formed substrate and a cover layer TX such as a fabric or synthetic material is applied to complete the panel base PB.
  • a substrate SB such as a structural substrate that is injection molded from a resin/polymer NP in a tool as a formed substrate with the separation area formed
  • an intermediate layer such as a foam layer FM is applied to the formed substrate
  • a cover layer TX such as a fabric or synthetic material is applied to complete the panel base PB.
  • the process of producing the component may be performed in a mold tool ME with a mold top section MT and a mold bottom section MB and with a tool MS shown comprising a slider arrangement SE; slider arrangement SL may be configured in tool MS to produce any of a variety of features in the base panel; slider arrangement SL may comprise a set or series of slider elements shown as blades BL that are configured (e.g. with shape, size, depth, arrangement, quantity, etc.) to produce the shape/form and profile of the connector and/or in a desired manner for substrate SB in resin NP.
  • the slider arrangement for the tool MS may be configured to provide features in the substrate SB such as a through-hole (see FIGURE 28D) or to form a gap/partial form (see FIGURE 29D) and/or to provide a profile/shape/form for the connector or other features of a variety of types/forms and positions. See FIGURES 9A-9C, 10A-10F, 11A-11F, 12A- 12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H.
  • a component C for an interior I for a vehicle V configured to facilitate deployment of an airbag AB may comprise a base comprising a base panel BP with a separation area SP.
  • the base may be configured to form a door ABD at the separation area SP of the base panel BP to provide an opening for deployment of the airbag through the base panel.
  • the separation area SP may comprise a set of segments SG. Each segment may comprise a connector CN of the door to the base panel. The connector CN of each segment SG may be configured to separate to facilitate formation of the opening.
  • Each segment may comprise features configured to selectively locate a stress concentration for rupture at the separation area during deployment.
  • the base of the component C may be configured to form the door ABD along the separation area SP of the base panel BP to provide the opening for deployment of the airbag through the base panel;
  • the separation area may be configured to define the opening for deployment of the airbag;
  • the separation area may be configured to define a shape of the opening for deployment of the airbag;
  • the separation area may be configured to define a shape of a flap for the door for deployment of the airbag;
  • the separation area may comprise a separation line SP/TR;
  • the separation line may comprise a seam;
  • the separation line may comprise a tear line.
  • each segment SG may comprise a connector CN between the door ABD and the base panel BP; each connector CN may comprise a connection section; each connector may comprise a separation section; the separation section may comprise a rupture area RP; each connector may comprise a rupture section RP/SP; each connector may comprise a bridge section; each connector may comprise a web section; each connector may comprise a web of material; each connector may comprise a bridge comprising a web of material; each connector may comprise a profile FP; each connector may comprise a shape; each connector may comprise a section; each segment may comprise a feature.
  • the feature may comprise a feature on the connector CN; each segment may comprise the connector and a feature; the feature may comprise a feature located adjacent to the connector; the feature at the segment may be configured to facilitate rupture of the connector at a rupture area RP of the segment.
  • the feature at the segment may comprise at least one of a gap FG, groove FN, countergroove, tapering FT, multi-dimensional tapering FT/FP, notch FN, counternotch, opening FG, aperture FG, cavity FG, rib FR, profile FP, shape FP, variation of width.
  • the feature at the segment may comprise at least one of a gap and/or a groove and/or an opening; the feature at the segment may comprise at least one of a groove and/or a countergroove and/or a rib; the feature at the segment may comprise at least one of tapering of the connector and/or multi-dimensional tapering of the connector and/or variation of width of the connector and/or variation of height of the connector; the feature at the segment may comprise tapering of the connector; the feature at the segment may comprise multi-dimensional tapering of the connector; the feature at the segment may comprise variation of width and/or height of the connector; the feature at the segment may comprise at least one of variation of thickness of the connector and/or variation of shape of the connector.
  • the feature at the segment may comprise at least one of a notch and/or a countemotch.
  • the feature at the segment SG may be configured to direct a stress concentration RC to a rupture area RP of the connector CN; the stress concentration may be sufficient to separate the door from the base panel at the rupture area; the stress concentration may be sufficient to rupture the seam of the base panel to form the door at the rupture area. See also FIGURES 32A-32B.
  • connection area comprising a connector CN may be provided between the base panel BP and the door ABD; the connector may comprise a trapezoidal shape; the connector may comprise a tapering shape; the connector may comprise a tapering profile FT/FP; the connector may comprise a curved profile; the connector may comprise a sloped profile; the connector may comprise a thin section at the separation area at the base panel.
  • the separation area SP of the base panel BP may be configured to comprise a relatively smooth separation surface SF after deployment of the airbag door ABD; the separation area may be configured to comprise a relatively smooth rupture area. See FIGURES 9A-9C. At deployment the separation area may be configured to may comprise a reduced size of stress concentration area for rupture. See FIGURES 13A-13H, 14A-14H, 15A-15H, 16A-16H and 32A-32B.
  • each segment may comprise a section comprising a gap and/or a section comprising a connector.
  • the connector may comprise a trapezoidal shape and the gap may comprise an aperture in the base panel adjacent the connector.
  • the aperture may comprise a shape comprising a middle portion between a first leg and a second leg. A height of the trapezoidal shape of the connector may be greater than a width of the middle portion of the aperture.
  • the aperture may comprise an obtuse angle between the first leg and the middle portion.
  • the first leg may comprise a length greater than a width of the middle portion.
  • the aperture may comprise a concave polygon shape.
  • the concave polygon shape may comprise more than six sides.
  • Each section may comprise a gap of a first distance and a section comprising a gap of a second distance and a connector comprising a tapering profile.
  • Each segment may comprise a bracket- shaped gap.
  • Each segment may comprise (a) a generally ]- shaped gap; (b) a generally ⁇ _/-shaped gap; or (c) a generally U shaped gap (a generally U- shaped gap).
  • Each segment may comprise a notch.
  • Each connector may comprise a tapered bridge; each connector may comprise a recess.
  • the connector may comprise a curved profile.
  • the connector may comprise a parabolic profile.
  • the connector may comprise a notch adjacent the separation area.
  • the connector may comprise a curved body.
  • the connector may comprise a thin section at the separation area.
  • the thin section may comprise a stress concentration sufficient to provide rupture at deployment of the airbag.
  • Each segment may be configured to form a separation surface at the opening in the base panel; each segment may be configured to form a projection at the airbag door.
  • the connector may comprise a varying size along the separation area.
  • the connector may comprise a varying profile along the separation area.
  • the connector may comprise a multi-dimensional profile.
  • Each segment may comprise a varying profile along the separation area.
  • Form of feature may vary along the separation area. Depth of the feature may vary along the separation area.
  • the rib may comprise a continuous rib around the airbag door.
  • the rib may be at the separation area.
  • the rib may comprise a stiffening rib.
  • the feature may comprise a slot.
  • the slot may comprise a bracket-shaped slot (]-shaped slot).
  • the connection area may be configured to develop a stress concentration during deployment of the airbag.
  • the stress concentration may be configured to establish a rupture area in the connection area.
  • the connector may be configured to rupture at the rupture area at deployment of the airbag.
  • the connector may comprise a profile configured to facilitate rupture of the connector at the rupture area of the segment.
  • the rupture may be at a designated area of the connector.
  • the seam may comprise a line.
  • the set of segments may be provided along the line.
  • the line may comprise a tear line.
  • the rupture may be at the seam.
  • the rupture may be at the tear line.
  • the connector may be configured to form a projection at deployment of the airbag.
  • the projection may comprise a tab.
  • the projection may be formed on the door.
  • Each segment may be configured to form a generally uniform tab on the door at deployment of the airbag.
  • the generally uniform tab of each segment may comprise a projection having substantially the same form at each segment.
  • the generally uniform tab of each segment may comprise a projection having substantially the same size at each segment.
  • the generally uniform tab of each segment may comprise a projection having substantially the same shape at each segment.
  • the panel BP may comprise a structural substrate SB; the structural substrate may comprise a molded substrate; the molded substrate may comprise an injection molded substrate; the base panel with the seam and the door may be integrally formed; the base panel with the seam and the door may be injection molded. See FIGURES 25, 30 and 31A-31C.
  • the structural substrate may be formed in an apparatus shown as mold ME; the base panel may be formed in an apparatus; the apparatus may comprise a mold; each segment may be formed in the base panel by a tool.
  • the tool may comprise a slider arrangement; the slider arrangement may be configured to form the seam in the base panel; the slider arrangement may comprise a slider configured to form a connector at each segment; the slider arrangement of the apparatus may be configured to form a feature at each segment.
  • the seam may comprise a weakening line.
  • the seam may comprise a tear line.
  • the structural substrate may be formed by a method.
  • the base panel may be formed by a method.
  • the method may comprise the steps of (a) forming the base panel and (b) forming a seam in the base panel to provide the door.
  • the seam may be formed by a tool.
  • the tool may comprise a slider arrangement.
  • the step of forming the seam in the base panel may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a connector at each segment.
  • the step of forming the set of segments in the base panel may comprise forming a feature at each segment.
  • the step of forming the base panel may comprise injection molding a resin material to form the base panel.
  • the component may comprise a hinge coupling the door to the base panel at deployment of the airbag.
  • the hinge HG may comprise reinforcement.
  • the reinforcement may comprise fabric.
  • the set of segments SG may be configured to form a weakening line SP/TR at the seam of the base panel BP.
  • the seam may comprise a weakening line in the base panel.
  • the seam may comprise a weakening area.
  • the seam may comprise a tear area.
  • the seam may comprise a separating area.
  • the seam may comprise a weakening area between the door and the base panel.
  • Each segment may comprise a connector comprising a connecting material.
  • the base may comprise a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of cavities in the rear side of the structural substrate.
  • the set of cavities may comprise at least one cavity comprising a profile. Each segment may comprise a cavity.
  • a method of producing a component configured for deployment of an airbag may comprise the steps of forming a base panel; and forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag. See also FIGURES 25, 26A-26D, 27A-27E. 28A-28D and 29A-29D.
  • the seam may be formed by a tool.
  • the step of forming the separation area in the base panel may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a connector at each segment.
  • the tool may comprise a slider arrangement.
  • the step of forming the separation area may comprise forming a seam in the base panel.
  • the step of forming the seam may comprise forming a set of segments in the base panel.
  • the step of forming the set of segments in the base panel may comprise forming a feature at each segment.
  • the step of forming the set of segments in the base panel may comprise forming a connector comprising a feature at each segment.
  • the step of forming the base panel may comprise injection molding a resin material to form the base panel.
  • the door may comprise an airbag door with a hinge provided in the base panel.
  • an apparatus for producing a component configured for deployment of an airbag may comprise a mold configured for forming a base panel and a tool configured for forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag; the tool may comprise a slider arrangement.
  • the separation area may comprise a seam; the seam may comprise a set of segments.
  • the slider arrangement SL may comprise a set of slider elements such as blades BL; the slider elements may comprise a set of blades; the slider elements may comprise elements of varying size and/or varying depth; the slider elements may comprise elements of varying shape; the slider elements may comprise elements of varying form.
  • the mold ML may comprise an injection mold; the mold may be configured to form the base panel from injection-molded resin NP.
  • the tool MS may be configured to form a set of segments for the seam; each segment may comprise a feature; the feature may comprise a connector; the feature may comprise a gap.
  • a component C for a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate SB formed to a base panel BP.
  • the structural substrate SB/BP may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line TR configured to provide a separation area SP for the opening for deployment of the airbag.
  • the line may comprise a set of segments in the structural substrate; each segment of the set of segments may comprise a feature.
  • the feature may be configured to facilitate formation of an opening in the structural substrate at the line for deployment of the airbag.
  • the line may comprise a tear line.
  • the line may comprise a separation line in the separation area.
  • the separation area may comprise a separation line.
  • the separation line may comprise a tear line.
  • Each segment of the set of segments may comprise a connector.
  • the connector may comprise a profile.
  • the feature may comprise the connector.
  • the feature may comprise a cavity.
  • the cavity may be formed in the rear side of the structural substrate.
  • the cavity may comprise a profile.
  • the structural substrate may comprise a base comprising a base panel.
  • the seam may comprise the set of segments; each segment may comprise a connector of the door to the base panel.
  • the connector of each segment may be configured to separate to facilitate formation of the opening.
  • the feature may comprise the connector.
  • the front side of the panel may comprise a contoured surface.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the feature may comprise a notch.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate.
  • the profile of the cavity may comprise a depth within the rear side of the structural substrate.
  • the profile of the cavity may comprise a curved surface.
  • the profile of the cavity may comprise a flat surface.
  • the profile of the cavity may comprise a curved shape.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • a component for a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a separation area for the opening for deployment of the airbag.
  • the separation area may comprise a set of gaps in the structural substrate.
  • the set of gaps may comprise at least one gap comprising a profile.
  • the separation area may comprise a line.
  • the separation area may comprise a separation line.
  • the separation line may comprise a tear line.
  • the separation line may comprise a seam.
  • the line may comprise a seam comprising a set of features.
  • the set of features may comprise a set of connectors.
  • the set of features may comprise the set of gaps and the set of connectors.
  • the profile of the connector may comprise a curved surface.
  • the profile of the connector may comprise a flat surface.
  • the profile of the connector may comprise a tapered shape.
  • the profile of the connector may comprise a curved shape.
  • the seam may comprise the tear line.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate.
  • the profile of the gap may comprise a curved surface.
  • the profile of the gap may comprise a flat surface.
  • the profile of the gap may comprise a curved shape.
  • the gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side.
  • the opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door
  • an airbag system for an interior of a vehicle configured for deployment of an airbag for an occupant of the vehicle upon an event may comprise (a) an airbag module ABM providing the airbag AB configured for deployment from the component C; and (b) a base of the component comprising a base panel BP with a seam SP/TR. See also FIGURES 5A-5C, 6A-6E, 7A-7G and 10A-10F.
  • the base may be configured to form a door ABD at the seam of the base panel to provide an opening for deployment of the airbag through the base panel.
  • the seam may comprise a set of segments SG; each segment may comprise a connector CN of the door to the base panel.
  • the connector of each segment may be configured to separate to facilitate formation of the opening; each segment may comprise a feature configured to facilitate formation of the opening for deployment of the airbag. See FIGURES 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H.
  • a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of cavities in the rear side of the structural substrate.
  • the set of cavities may comprise at least one cavity comprising a profile.
  • the front side of the panel may comprise a substantially planar surface opposite the at least one cavity.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate.
  • the profile of the cavity may comprise a depth within the rear side of the structural substrate.
  • the profile of the cavity may comprise a curved surface.
  • the profile of the cavity may comprise a flat surface.
  • the profile of the cavity may comprise a curved shape.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
  • the structural substrate may comprise a rear side facing the airbag and a front side providing a surface.
  • the rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag.
  • the structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag.
  • the line may comprise a set of gaps in the structural substrate.
  • the set of gaps may comprise at least one gap comprising a profile.
  • the tear line may comprise at least one of (a) a weakening line or (b) a weakened section.
  • the line may comprise a set of notches in the front side of the structural substrate.
  • the set of notches may comprise at least one notch comprising a profile.
  • the set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate.
  • the set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate.
  • the profile of the gap may comprise a curved surface.
  • the profile of the gap may comprise a flat surface.
  • the profile of the gap may comprise a curved shape.
  • the gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side.
  • the opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface.
  • the component may comprise a cover over the structural substrate.
  • the cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface.
  • the outer surface may be configured so that the line is not readily perceptible at the outer surface.
  • the component may comprise an intermediate layer between the cover and the structural substrate.
  • the intermediate layer may comprise at least one of (a) a foam; (b) a textile.
  • the structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
  • the rear side of the structural substrate may be configured to support an airbag module.
  • the component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door
  • the present invention relates to a vehicle interior component, a method for manufacturing said vehicle interior component and a mold to form said vehicle interior component.
  • the component may comprise a trim component.
  • the component may comprise a cover, an intermediate layer and a substrate.
  • the cover may comprise an exterior cover layer.
  • the intermediate layer may comprise a functional layer.
  • the substrate may comprise an area configured to enable an airbag deployment.
  • the area may comprise a structure configured to be a weakening of the substrate.
  • the weakening may comprise a specific weakening structure.
  • the design of the weakening structure is configured to be manufactured by injection molding process.
  • An injection molding process and tool are disclosed. They are configured to manufacture the weakening structure formed in the substrate.
  • the tool may comprise sliders.
  • the method may comprise the sequence of the manufacturing steps.
  • a method for use of the component may comprise closing the mold, injecting resin, moving slider(s), forming a substrate, demolding the substrate, foaming on the substrate (optional), and laminating a cover to the substrate.
  • the present inventions may comprise conventional technology (e.g. as implemented and/or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may comprise any other applicable technology (present and/or future) with suitability and/or capability to perform the functions and processes/operations described in the specification and/or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.

Abstract

A component for a vehicle interior may comprise a base panel. At deployment of an airbag a door may form at a separation area of the base panel to provide an opening for airbag deployment. The separation area may comprise a set of segments. Each segment may comprise a connector of the door to the base panel configured to separate to facilitate formation of the opening. Each segment may comprise features to selectively locate a stress concentration for rupture at the separation area during deployment. Each segment may comprise a connector between the door and the base panel. The connector may comprise a trapezoidal shape. The connector may comprise a parabolic profile. The connector may comprise a thin section at the separation area at the base panel. The separation area may comprise a relatively smooth separation surface after airbag deployment. Each segment may comprise a generally bracket-shaped (]-shaped) gap.

Description

PATENT APPLICATION
COMPONENT FOR VEHICLE INTERIOR
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to and incorporates by reference in full the following patent application: U.S. Provisional Patent Application No. 63/304,414 titled “VEHICLE INTERIOR COMPONENT” filed January 28, 2022.
FIELD
[0002] The present invention relates to a component for a vehicle interior.
[0003] The present invention also relates to component for a vehicle interior configured to facilitate deployment of an airbag into the vehicle interior.
BACKGROUND
[0004] It is known to provide component for a vehicle interior configured to facilitate deployment of an airbag into the vehicle interior.
[0005] It would be advantageous to provide an improved component for a vehicle interior configured to facilitate deployment of an airbag into the vehicle interior.
[0006] It would also be advantageous to provide for an improved component for a vehicle interior comprising a base panel configured to form a door for deployment of the airbag. [0007] It would also be advantageous to provide for an improved component for a vehicle interior comprising a base panel providing a separation area with a set of segments configured to form a door for deployment of the airbag into the interior.
[0008] It would also be advantageous to provide for an improved component for a vehicle interior comprising a base panel providing a separation area with a set of segments comprising a connector and/or feature configured to form a door for deployment of the airbag into the interior.
[0009] It would also be advantageous to provide for an improved component for a vehicle interior comprising a base panel providing a separation area with a set of segments comprising a connector and/or feature configured to direct a stress concentration to provide a rupture of the base panel to form a door for deployment of the airbag into the interior. SUMMARY
[0010] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a base comprising a base panel with a separation area. At deployment of the airbag the base may be configured to form a door at the separation area of the base panel to provide an opening for deployment of the airbag through the base panel. The separation area may comprise a set of segments. Each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. Each segment may comprise features configured to selectively locate a stress concentration for rupture at the separation area during deployment. At deployment of the airbag the base may be configured to form the door along the separation area of the base panel to provide the opening for deployment of the airbag through the base panel. The separation area may be configured to define the opening for deployment of the airbag. The separation area may be configured to define a shape of the opening for deployment of the airbag. The separation area may be configured to define a shape of a flap for the door for deployment of the airbag. The separation area may comprise a separation line. The separation line may comprise a seam. The separation line may comprise a tear line. Each segment may comprise a connector between the door and the base panel. Each connector may comprise a connection section. Each connector may comprise a separation section. The separation section may comprise a rupture area. Each connector may comprise a rupture section. Each connector may comprise a bridge section. Each connector may comprise a web section. Each connector may comprise a web of material. Each connector may comprise a bridge comprising a web of material. Each connector may comprise a profile. Each connector may comprise a shape. Each connector may comprise a section. Each segment may comprise a feature. The feature may comprise a feature on the connector. Each segment may comprise the connector and a feature. The feature may comprise a feature located adjacent to the connector. The feature at the segment may be configured to facilitate rupture of the connector at a rupture area of the segment. The feature at the segment may comprise at least one of a gap, groove, countergroove, tapering, multidimensional tapering, notch, counternotch, opening, aperture, cavity, rib, profile, shape, variation of width. The feature at the segment may comprise at least one of a gap and/or a groove and/or an opening. The feature at the segment may comprise at least one of a groove and/or a countergroove and/or a rib. The feature at the segment may comprise at least one of tapering of the connector and/or multi-dimensional tapering of the connector and/or variation of width of the connector and/or variation of height of the connector. The feature at the segment may comprise tapering of the connector. The feature at the segment may comprise multi-dimensional tapering of the connector. The feature at the segment may comprise variation of width and/or height of the connector. The feature at the segment may comprise at least one of variation of thickness of the connector and/or variation of shape of the connector. The feature at the segment may comprise at least one of a notch and/or a countemotch. The feature at the segment may be configured to direct a stress concentration to a rupture area of the connector. The stress concentration may be sufficient to separate the door from the base panel at the rupture area. The stress concentration may be sufficient to rupture the seam of the base panel to form the door at the rupture area. The connection area may be provided between the base panel and the door. The connector may comprise a trapezoidal shape. The connector may comprise a tapering shape. The connector may comprise a tapering profile. The connector may comprise a curved profile. The connector may comprise a sloped profile. The connector may comprise a thin section at the separation area at the base panel. The separation area of the base panel may be configured to comprise a relatively smooth separation surface after deployment of the airbag door. The separation area may be configured to comprise a relatively smooth rupture area. At deployment the separation area may be configured to may comprise a reduced size of stress concentration area for rupture. Each segment may comprise a section comprising a gap and a section comprising a connector. The connector may comprise a trapezoidal shape and the gap may comprise an aperture in the base panel adjacent the connector. The aperture may comprise a shape comprising a middle portion between a first leg and a second leg. A height of the trapezoidal shape of the connector may be greater than a width of the middle portion of the aperture. The aperture may comprise an obtuse angle between the first leg and the middle portion. The first leg may comprise a length greater than a width of the middle portion. The aperture may comprise a concave polygon shape. The concave polygon shape may comprise more than six sides. Each section may comprise a gap of a first distance and a section comprising a gap of a second distance and a connector comprising a tapering profile. Each segment may comprise a bracket- shaped gap. Each segment may comprise (a) a generally ]- shaped gap; (b) a generally \_/ shaped gap; or (c) a generally U shaped gap. Each segment may comprise a notch. Each connector may comprise a tapered bridge. Each connector may comprise a recess. The connector may comprise a curved profile. The connector may comprise a parabolic profile. The connector may comprise a notch adjacent the separation area. The connector may comprise a curve body. The connector may comprise a thin section at the separation area. The thin section may comprise a stress concentration sufficient to provide rupture at deployment of the airbag. Each segment may be configured to form a separation surface at the opening in the base panel. Each segment may be configured to form a projection at the airbag door. The connector may comprise a varying size along the separation area. The connector may comprise a varying profile along the separation area. The connector may comprise a multi-dimensional profile. Each segment may comprise a varying profile along the separation area. Form of feature may vary along the separation area. Depth of the feature may vary along the separation area. The rib may comprise a continuous rib around the airbag door. The rib may be at the separation area. The rib may comprise a stiffening rib. The feature may comprise a slot. The slot may comprise a bracketshaped slot. The connection area may be configured to develop a stress concentration during deployment of the airbag. The stress concentration may be configured to establish a rupture area in the connection area. The connector may be configured to rupture at the rupture area at deployment of the airbag. The connector may comprise a profile configured to facilitate rupture of the connector at the rupture area of the segment. The rupture may be at a designated area of the connector. The seam may comprise a line. The set of segments may be provided along the line. The line may comprise a tear line. The rupture may be at the seam. The rupture may be at the tear line. The connector may be configured to form a projection at deployment of the airbag. The projection may comprise a tab. The projection may be formed on the door. Each segment may be configured to form a generally uniform tab on the door at deployment of the airbag. The generally uniform tab of each segment may comprise a projection having substantially the same form at each segment. The generally uniform tab of each segment may comprise a projection having substantially the same size at each segment. The generally uniform tab of each segment may comprise a projection having substantially the same shape at each segment. The panel may comprise a structural substrate. The structural substrate may comprise a molded substrate. The molded substrate may comprise an injection molded substrate. The base panel with the seam and the door may be integrally formed. The base panel with the seam and the door may be injection molded. The structural substrate may be formed in an apparatus. The base panel may be formed in an apparatus. The apparatus may comprise a mold. Each segment may be formed in the base panel by a tool. The tool may comprise a slider arrangement. The slider arrangement may be configured to form the seam in the base panel. The slider arrangement may comprise a slider configured to form a connector at each segment. The slider arrangement of the apparatus may be configured to form a feature at each segment. The seam may comprise a weakening line. The seam may comprise a tear line. The structural substrate may be formed by a method. The base panel may be formed by a method. The method may comprise the steps of (a) forming the base panel and (b) forming a seam in the base panel to provide the door. The seam may be formed by a tool. The tool may comprise a slider arrangement. The step of forming the seam in the base panel may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a connector at each segment. The step of forming the set of segments in the base panel may comprise forming a feature at each segment. The step of forming the base panel may comprise injection molding a resin material to form the base panel. The component may comprise a hinge coupling the door to the base panel at deployment of the airbag. The hinge may comprise reinforcement. The reinforcement may comprise fabric. The set of segments may be configured to form a weakening line at the seam of the base panel. The seam may comprise a weakening line in the base panel. The seam may comprise a weakening area. The seam may comprise a tear area. The seam may comprise a separating area. The seam may comprise a weakening area between the door and the base panel. Each segment may comprise a connector comprising a connecting material. The base may comprise a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of cavities in the rear side of the structural substrate. The set of cavities may comprise at least one cavity comprising a profile. Each segment may comprise a cavity.
[0011] The present invention relates to a method of producing a component configured for deployment of an airbag comprising the steps of forming a base panel; and forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag. The seam may be formed by a tool. The step of forming the separation area in the base panel may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a connector at each segment. The tool may comprise a slider arrangement. The step of forming the separation area may comprise forming a seam in the base panel. The step of forming the seam may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a feature at each segment. The step of forming the set of segments in the base panel may comprise forming a connector comprising a feature at each segment. The step of forming the base panel may comprise injection molding a resin material to form the base panel. The door may comprise an airbag door with a hinge provided in the base panel.
[0012] The present invention relates to an apparatus for producing a component configured for deployment of an airbag comprising a mold configured for forming a base panel and a tool configured for forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag. The tool may comprise a slider arrangement. The separation area may comprise a seam. The seam may comprise a set of segments. The slider arrangement may comprise a set of slider elements. The slider elements may comprise a set of blades. The slider elements may comprise elements of varying size and/or varying depth. The slider elements may comprise elements of varying shape. The slider elements may comprise elements of varying form. The mold may comprise an injection mold; the mold may be configured to form the base panel from injection-molded resin. The tool may be configured to form a set of segments for the seam. Each segment may comprise a feature. The feature may comprise a connector. The feature may comprise a gap.
[0013] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a separation area for the opening for deployment of the airbag. The line may comprise a set of segments in the structural substrate. Each segment of the set of segments may comprise a feature. The feature may be configured to facilitate formation of an opening in the structural substrate at the line for deployment of the airbag. The line may comprise a tear line. The line may comprise a separation line in the separation area. The separation area may comprise a separation line. The separation line may comprise a tear line. Each segment of the set of segments may comprise a connector. The connector may comprise a profile. The feature may comprise the connector. The feature may comprise a cavity. The cavity may be formed in the rear side of the structural substrate. The cavity may comprise a profile. The structural substrate may comprise a base comprising a base panel. The line may comprise a seam. At deployment of the airbag the base may be configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel. The seam may comprise the set of segments. Each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. The feature may comprise the connector. The front side of the panel may comprise a contoured surface. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The feature may comprise a notch. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate. The profile of the cavity may comprise a depth within the rear side of the structural substrate. The profile of the cavity may comprise a curved surface. The profile of the cavity may comprise a flat surface. The profile of the cavity may comprise a curved shape. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar. [0014] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a separation area for the opening for deployment of the airbag. The separation area may comprise a set of gaps in the structural substrate. The set of gaps may comprise at least one gap comprising a profile. The separation area may comprise a line. The separation area may comprise a separation line. The separation line may comprise a tear line. The separation line may comprise a seam. The line may comprise a seam comprising a set of features. The set of features may comprise a set of connectors. The set of features may comprise the set of gaps and the set of connectors. The profile of the connector may comprise a curved surface. The profile of the connector may comprise a flat surface. The profile of the connector may comprise a tapered shape. The profile of the connector may comprise a curved shape. The seam may comprise the tear line. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate. The profile of the gap may comprise a curved surface. The profile of the gap may comprise a flat surface. The profile of the gap may comprise a curved shape. The gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side. The opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0015] The present invention relates to an airbag system for an interior of a vehicle configured for deployment of an airbag for an occupant of the vehicle upon an event comprising (a) an airbag module providing the airbag configured for deployment from the component; and (b) a base of the component comprising a base panel with a seam. At deployment of the airbag the base may be configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel. The seam may comprise a set of segments. Each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. Each segment may comprise a feature configured to facilitate formation of the opening for deployment of the airbag.
[0016] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of cavities in the rear side of the structural substrate. The set of cavities may comprise at least one cavity comprising a profile. The front side of the panel may comprise a substantially planar surface opposite the at least one cavity. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate. The profile of the cavity may comprise a depth within the rear side of the structural substrate. The profile of the cavity may comprise a curved surface. The profile of the cavity may comprise a flat surface. The profile of the cavity may comprise a curved shape. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0017] The present invention relates to a component for a vehicle interior configured to facilitate deployment of an airbag comprising a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of gaps in the structural substrate. The set of gaps may comprise at least one gap comprising a profile. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate. The profile of the gap may comprise a curved surface. The profile of the gap may comprise a flat surface. The profile of the gap may comprise a curved shape. The gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side. The opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
FIGURES
[0018] FIGURE 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.
[0019] FIGURE IB is schematic partial perspective view of a vehicle interior according to an exemplary embodiment.
[0020] FIGURES 2A and 2B are schematic partial perspective views of a vehicle interior according to an exemplary embodiment.
[0021] FIGURE 3A is a schematic perspective view of a component for a vehicle interior shown as an instrument panel according to an exemplary embodiment.
[0022] FIGURES 3B through 3D are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.
[0023] FIGURES 4A through 4F are schematic perspective views of a deployment of an airbag from a vehicle interior component according to an exemplary embodiment.
[0024] FIGURE 5A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0025] FIGURE 5B is schematic exploded perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0026] FIGURE 5C is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
[0027] FIGURE 6A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0028] FIGURE 6B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0029] FIGURE 6C is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
[0030] FIGURE 6D is schematic partial section view of a component for a vehicle interior according to an exemplary embodiment.
[0031] FIGURE 6E is schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0032] FIGURE 7A is schematic perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0033] FIGURE 7B is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment. [0034] FIGURE 7C is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0035] FIGURE 7D is schematic partial perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0036] FIGURE 7E is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0037] FIGURE 7F is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0038] FIGURE 7G is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0039] FIGURES 8A through 8C are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
[0040] FIGURES 9A through 9C are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
[0041] FIGURES 10A through 10F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0042] FIGURES 11 A through 1 IF are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0043] FIGURES 12A through 12F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0044] FIGURE 13A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0045] FIGURE 13B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0046] FIGURE 13C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0047] FIGURE 13D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
[0048] FIGURES 13E and 13F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0049] FIGURES 13G and 13H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
[0050] FIGURE 14A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment. [0051] FIGURE 14B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0052] FIGURE 14C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0053] FIGURE 14D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
[0054] FIGURES 14E and 14F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0055] FIGURES 14G and 14H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
[0056] FIGURE 15A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0057] FIGURE 15B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0058] FIGURE 15C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0059] FIGURE 15D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
[0060] FIGURES 15E and 15F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0061] FIGURES 15G and 15H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment.
[0062] FIGURE 16A is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0063] FIGURE 16B is schematic partial section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0064] FIGURE 16C is schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0065] FIGURE 16D is schematic partial plan view of a component for a vehicle interior according to an exemplary embodiment.
[0066] FIGURES 16E and 16F are schematic partial section views of a component for a vehicle interior according to an exemplary embodiment.
[0067] FIGURES 16G and 16H are schematic partial section views of a section of a component for a vehicle interior according to an exemplary embodiment. [0068] FIGURES 17A through 17D are schematic cutaway perspective views of a component for a vehicle interior according to an exemplary embodiment.
[0069] FIGURES 18A and 18B are schematic cutaway plan views of a component for a vehicle interior according to an exemplary embodiment.
[0070] FIGURE 19 is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0071] FIGURE 20 is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0072] FIGURE 21 A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0073] FIGURE 21B is a schematic cutaway section perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0074] FIGURE 21C is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0075] FIGURE 21D is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0076] FIGURE 22A is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0077] FIGURE 22B is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0078] FIGURE 22C is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0079] FIGURE 22D is a schematic cutaway plan view of a component for a vehicle interior according to an exemplary embodiment.
[0080] FIGURE 22E is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0081] FIGURE 22F is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0082] FIGURE 23A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0083] FIGURE 23B is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0084] FIGURE 23C is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment. [0085] FIGURE 23D is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0086] FIGURE 23E is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0087] FIGURE 23F is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0088] FIGURE 24A is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0089] FIGURE 24B is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0090] FIGURE 24C is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0091] FIGURE 24D is a schematic cutaway perspective view of a component for a vehicle interior according to an exemplary embodiment.
[0092] FIGURE 24E is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0093] FIGURE 24F is a schematic cutaway section view of a component for a vehicle interior according to an exemplary embodiment.
[0094] FIGURE 25 is a schematic exploded perspective view of a tool/apparatus configured to a produce a component for a vehicle interior according to an exemplary embodiment.
[0095] FIGURES 26A through 26D are schematic section views of a tool/apparatus configured to a produce a component for a vehicle interior according to an exemplary embodiment.
[0096] FIGURES 27A through 27D are schematic perspective views of a tool configured to a produce a component for a vehicle interior according to an exemplary embodiment.
[0097] FIGURE 27E is schematic cutaway perspective view of a tool configured to a produce a component for a vehicle interior according to an exemplary embodiment.
[0098] FIGURES 28 A through 28C are schematic section views of a method of producing a component for a vehicle interior according to an exemplary embodiment.
[0099] FIGURE 28D is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.
[0100] FIGURES 29A through 29C are schematic section views of a method of producing a component for a vehicle interior according to an exemplary embodiment. [0101] FIGURE 29D is a schematic section view of a component for a vehicle interior according to an exemplary embodiment.
[0102] FIGURE 30 is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
[0103] FIGURE 31 A is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
[0104] FIGURE 3 IB is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
[0105] FIGURE 31C is a schematic flow chart of a method of producing a component for a vehicle interior according to an exemplary embodiment.
[0106] FIGURES 32A and 32B are schematic partial section views of a segment of a panel of a component for a vehicle interior indicating a stress concentration under load of deployment of an airbag through the panel of the component according to an exemplary embodiment.
DESCRIPTION
[0107] Referring to FIGURES 1A-1B and 2A-2B, a vehicle V is shown with an interior I comprising components C such as an instrument panel IP, door panel DP, steering wheel SW, seats ST, and other trim panels/components.
[0108] As shown schematically according to an exemplary embodiment in FIGURES IB, 2A-2B, 3A-3D and 4A-4D, the components of the interior of the vehicle may be configured for deployment of an airbag AB such as from an airbag assembly/module ABM through an opening formed by a door ABD at a separation area shown as weakening/tear line TR in the component shown as instrument panel C/IP (e.g. deployment of airbag upon detection of an event).
[0109] As shown schematically according to an exemplary embodiment in FIGURES 5A-5C and 6A-6C, the component such as instrument panel C/IP may comprise a base panel BP shown as comprising a structural substrate SB and an intermediate layer shown as a foam layer FM and a cover shown as cover layer TX; the component C with base panel BP may be configured for an installation of an airbag system/assembly such as within housing HN (e.g. assembled to the component) for deployment of an airbag AB through an opening formed by the airbag door ABD at the separation area/line TR upon actuation of an inflator NF. See also FIGURES 4A-4F (deployment of airbag from airbag system/module through door/opening formed in base panel of component). As indicated schematically, the intermediate layer may comprise any of a variety of materials such as a foam material/layer, spacer, fabric, soft layer, functional layer, sensor layer, haptic layer, other material/layer/combination, etc.); the cover layer may be any of a variety of materials including fabric, leather, synthetic leather, plastic/polymer materials, films, etc. See also FIGURES 23A-23F and 24A-24F.
[0110] As indicated schematically according to an exemplary embodiment in FIGURES 6A- 6E and 7A-7G, the component C may comprise the base panel BP with a separation area/line SP/TR comprising a set of segments SG configured for formation of the airbag door ABD at deployment of the airbag AB; each segment SG of the set of segments may comprise a connector CN shown as a bridge (e.g. material, web, etc.) configured to connect the airbag door ABD to the base panel BP; each segment of the set of segments may comprise a feature such as a profile/shape FP for connector CN and a gap FG at or adjacent to connector CN and/or a notch FN at or adjacent to connector CN and/or other feature within the segment SG. See also FIGURES 9A-9C. As indicated schematically in FIGURES 7C-7G, 9A-9C and 10A-10F, at deployment of the airbag the airbag door ABD will be formed in the base panel BP at and along the separation area/line TR provided by the set of segments SG; a rupture RR will form at the connector CN at each segment SG and airbag door ABD will separate from base panel BP. See also FIGURES 4A-4F.
[0111] As indicated schematically in FIGURES 7C-7G, 9A-9C, 10A-10F, 11A-11F and 12A-12F, at each segment SG along the separation line SP/TR at deployment of the airbag a separation is intended to develop at or adjacent to a feature such as gap FG and/or profile FP of connector CN; as indicated schematically, relative position/relationship and type/shape and form/profile of the connector and/or the feature of the segment will direct a stress concentration to a separation area SP/TR at the segment to form a rupture area RP and rupture RR to facilitate formation of the opening and airbag door ABD along the separation area/line SP. See also FIGURES 13A-13H, 14A-14H, 15A-15H, 16A-16H and 32A-32B. [0112] As indicated schematically 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A- 14H, 15A-15H and 16A-16H, the combination/relationship of the feature and the connector CN such as the configuration of the gap FG or the presence of a notch FN or the shape/profile of the connector CN such as taper FT may be arranged to facilitate location of the separation area SP/rupture area RP for rupture RR at an intended position at the segment SG and/or on the connector CN. See also FIGURES 21A-21D and 22A-22F. As indicated schematically in FIGURES 7A-7F, 9A-9C and 17A-17D, the segments SG of the separation area SP/TR can be configured with a connector CN and features such as profile FP and/or notch FN in an arrangement intended to provide a selectively-located rupture area RP at deployment of the airbag AB (e.g. as without projections into the opening in the base panel for airbag deployment) and/or a more generally uniform shape/form of projections CN/PR from the airbag door (e.g. without substantial residual on the base panel, with substantial entirety of body on the airbag door, with less chipping/fragmentation, etc.). See also FIGURES 21A- 21D and 22A-22F.
[0113] As indicated schematically in FIGURES 7E-7F, the separation of the airbag door ABD from the base panel BP at the separation area SP/TR will produce a separation surface SF on the base panel BP and a projection CN/PR on the airbag door ABD. Compare FIGURES 8A-8C and 9A-9C. As indicated schematically in FIGURES 8A-8C, separation at a tear line TR within a segment SG may produce an irregular shape/form of surfaces SF and/or projections CN/PR at each side of the separation (including at the base panel as may project into the opening for the airbag deployment); such irregularities such as from projections or surfaces at the tear line may contact and damage /affect or impede the deployment of the airbag (e.g. if projecting into the opening for the airbag deployment). As indicated schematically in FIGURES 9A-9C, separation at a tear line TR within a segment SG with a connector CN and a gap FG (shown as generally bracket-shaped/]-shaped gap) may produce a generally uniform and/or regular shape/form and position/placement of surfaces SF and or projections CN/PR on the airbag door ABD; such general uniformity such as from projections CN/PR on the airbag door and uniform surfaces SF at the tear line may reduce the potential for contact as would impede deployment or may damage the airbag (e.g. with no projections from the connector projecting into the opening for the airbag deployment); as indicated in FIGURES 9A-9C, the form/location of the gap FG in relation to the location/profile FP of the connector CN may be configured and/or combined to provide a set or surfaces SF along the base panel BP that do not extend into the opening for the airbag (e.g. within the separation line TR and within surfaces forming gap FG). See also FIGURES 7B-7F and 17A-17D.
[0114] As indicated schematically in FIGURES 6D-6E, 7C-7D and 12A-12F, the airbag door ABD may comprise a feature such as a rib FR and/or other rigidifying material (such as a grid/web, frame, border, etc.) and/or a reinforcement such as a fabric sheet for a hinge HG at the attachment to the base panel BP. As indicated schematically in FIGURES 11A-11F, the airbag door ABD may be formed with a generally uniform door without a rib/member. As indicated schematically in FIGURES 11A-11F and 12A-12F, the segments SG of the separation area SP can be configured with a connector CN and features such as profile FP or notch FN in an arrangement intended to provide a selectively-located rupture area RP at deployment of the airbag AB (e.g. as without projections into the opening in the base panel for airbag deployment) and/or a more generally uniform shape/form of projections CN/PR from the airbag door (e.g. without substantial residual on the base panel, with substantial entirety of body on the airbag door, with less chipping/fragmentation, etc.). See also FIGURES 7A-7F, 9A-9C and 17A-17D.
[0115] As indicated schematically in FIGURES 14A-14H, 15A-15H and 16A-16H, configuration of each segment SG of the separation area/line SP/TR with connector CN with profile FP (shown as curved profile/shape) and adjacent features such as rib FR and notch FN and etc. may provide for a directed/localized stress concentration RC within the segment intended to facilitate directed/localized separation/rupture. See also FIGURES 32A-32B. As indicated in FIGURES 7A-7F, 10A-10F, 18A-18B, 19 and 20, the segments SG of the separation area for the airbag door ABD of base panel BP may be sized/shaped and configured in a variety of arrangements to facilitate the deployment of an airbag for the component. See also FIGURES 21A-21D and 22A-22F. [0116] As shown schematically according to an exemplary embodiment in FIGURES 13G- 13H, 14G-14H, 15G-15H, 16G-16H and 32A-32B, a stress concentration RC may be produced at a segment of the separation line of a panel of a component under load of deployment of an airbag through the panel of the component; as indicated schematically, stress concentration RC-1 is a sufficient stress concentration as may produce a rupture at the location of the stress concentration (stress concentration RC-2 and RC-3 are progressively lower stress concentrations); configuration of the segment with form/profile and shape/size of the connector and feature may be arranged to direct the stress concentration within the segment to produce separation/rupture at or within an intended region. See also FIGURES 7A-7F and 9A-9C.
[0117] As indicated schematically in FIGURES 5A-5C, 23A-23F, 24A-24F, 26A-26D, 30 and 31A-31C, the component may be formed from a process as with a substrate SB such as a structural substrate that is injection molded from a resin/polymer NP in a tool as a formed substrate with the separation area formed; an intermediate layer such as a foam layer FM is applied to the formed substrate and a cover layer TX such as a fabric or synthetic material is applied to complete the panel base PB. As indicated in FIGURES 25, 26A-26D, 27A-27E, 28A-28D, 29A-29D, 30 and 31A-31C, the process of producing the component may be performed in a mold tool ME with a mold top section MT and a mold bottom section MB and with a tool MS shown comprising a slider arrangement SE; slider arrangement SL may be configured in tool MS to produce any of a variety of features in the base panel; slider arrangement SL may comprise a set or series of slider elements shown as blades BL that are configured (e.g. with shape, size, depth, arrangement, quantity, etc.) to produce the shape/form and profile of the connector and/or in a desired manner for substrate SB in resin NP. Compare FIGURES 18A, 19 and 20 with FIGURES 27A-27E (formed substrate/panel with slider arrangement configuration). As indicated schematically in FIGURES 28A-28D and 29A-29D, the slider arrangement for the tool MS may be configured to provide features in the substrate SB such as a through-hole (see FIGURE 28D) or to form a gap/partial form (see FIGURE 29D) and/or to provide a profile/shape/form for the connector or other features of a variety of types/forms and positions. See FIGURES 9A-9C, 10A-10F, 11A-11F, 12A- 12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H.
Exemplary Embodiments - A
[0118] According to an exemplary embodiment as shown schematically in FIGURE 1A-1B, 2A-2B, 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, a component C for an interior I for a vehicle V configured to facilitate deployment of an airbag AB may comprise a base comprising a base panel BP with a separation area SP. At deployment of the airbag the base may be configured to form a door ABD at the separation area SP of the base panel BP to provide an opening for deployment of the airbag through the base panel. The separation area SP may comprise a set of segments SG. Each segment may comprise a connector CN of the door to the base panel. The connector CN of each segment SG may be configured to separate to facilitate formation of the opening. Each segment may comprise features configured to selectively locate a stress concentration for rupture at the separation area during deployment.
[0119] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, at deployment of the airbag AB the base of the component C may be configured to form the door ABD along the separation area SP of the base panel BP to provide the opening for deployment of the airbag through the base panel; the separation area may be configured to define the opening for deployment of the airbag; the separation area may be configured to define a shape of the opening for deployment of the airbag; the separation area may be configured to define a shape of a flap for the door for deployment of the airbag; the separation area may comprise a separation line SP/TR; the separation line may comprise a seam; the separation line may comprise a tear line.
[0120] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, each segment SG may comprise a connector CN between the door ABD and the base panel BP; each connector CN may comprise a connection section; each connector may comprise a separation section; the separation section may comprise a rupture area RP; each connector may comprise a rupture section RP/SP; each connector may comprise a bridge section; each connector may comprise a web section; each connector may comprise a web of material; each connector may comprise a bridge comprising a web of material; each connector may comprise a profile FP; each connector may comprise a shape; each connector may comprise a section; each segment may comprise a feature.
[0121] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, the feature may comprise a feature on the connector CN; each segment may comprise the connector and a feature; the feature may comprise a feature located adjacent to the connector; the feature at the segment may be configured to facilitate rupture of the connector at a rupture area RP of the segment. The feature at the segment may comprise at least one of a gap FG, groove FN, countergroove, tapering FT, multi-dimensional tapering FT/FP, notch FN, counternotch, opening FG, aperture FG, cavity FG, rib FR, profile FP, shape FP, variation of width. The feature at the segment may comprise at least one of a gap and/or a groove and/or an opening; the feature at the segment may comprise at least one of a groove and/or a countergroove and/or a rib; the feature at the segment may comprise at least one of tapering of the connector and/or multi-dimensional tapering of the connector and/or variation of width of the connector and/or variation of height of the connector; the feature at the segment may comprise tapering of the connector; the feature at the segment may comprise multi-dimensional tapering of the connector; the feature at the segment may comprise variation of width and/or height of the connector; the feature at the segment may comprise at least one of variation of thickness of the connector and/or variation of shape of the connector. The feature at the segment may comprise at least one of a notch and/or a countemotch.
[0122] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, the feature at the segment SG may be configured to direct a stress concentration RC to a rupture area RP of the connector CN; the stress concentration may be sufficient to separate the door from the base panel at the rupture area; the stress concentration may be sufficient to rupture the seam of the base panel to form the door at the rupture area. See also FIGURES 32A-32B.
[0123] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, the connection area comprising a connector CN may be provided between the base panel BP and the door ABD; the connector may comprise a trapezoidal shape; the connector may comprise a tapering shape; the connector may comprise a tapering profile FT/FP; the connector may comprise a curved profile; the connector may comprise a sloped profile; the connector may comprise a thin section at the separation area at the base panel.
[0124] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, the separation area SP of the base panel BP may be configured to comprise a relatively smooth separation surface SF after deployment of the airbag door ABD; the separation area may be configured to comprise a relatively smooth rupture area. See FIGURES 9A-9C. At deployment the separation area may be configured to may comprise a reduced size of stress concentration area for rupture. See FIGURES 13A-13H, 14A-14H, 15A-15H, 16A-16H and 32A-32B.
[0125] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, each segment may comprise a section comprising a gap and/or a section comprising a connector. The connector may comprise a trapezoidal shape and the gap may comprise an aperture in the base panel adjacent the connector. The aperture may comprise a shape comprising a middle portion between a first leg and a second leg. A height of the trapezoidal shape of the connector may be greater than a width of the middle portion of the aperture. The aperture may comprise an obtuse angle between the first leg and the middle portion. The first leg may comprise a length greater than a width of the middle portion. The aperture may comprise a concave polygon shape. The concave polygon shape may comprise more than six sides. Each section may comprise a gap of a first distance and a section comprising a gap of a second distance and a connector comprising a tapering profile. Each segment may comprise a bracket- shaped gap. Each segment may comprise (a) a generally ]- shaped gap; (b) a generally \_/-shaped gap; or (c) a generally U shaped gap (a generally U- shaped gap). Each segment may comprise a notch. Each connector may comprise a tapered bridge; each connector may comprise a recess. The connector may comprise a curved profile. The connector may comprise a parabolic profile. The connector may comprise a notch adjacent the separation area. The connector may comprise a curved body. The connector may comprise a thin section at the separation area. The thin section may comprise a stress concentration sufficient to provide rupture at deployment of the airbag. Each segment may be configured to form a separation surface at the opening in the base panel; each segment may be configured to form a projection at the airbag door. The connector may comprise a varying size along the separation area. The connector may comprise a varying profile along the separation area. The connector may comprise a multi-dimensional profile. Each segment may comprise a varying profile along the separation area. Form of feature may vary along the separation area. Depth of the feature may vary along the separation area. The rib may comprise a continuous rib around the airbag door. The rib may be at the separation area. The rib may comprise a stiffening rib. The feature may comprise a slot. The slot may comprise a bracket-shaped slot (]-shaped slot). The connection area may be configured to develop a stress concentration during deployment of the airbag. The stress concentration may be configured to establish a rupture area in the connection area. The connector may be configured to rupture at the rupture area at deployment of the airbag. The connector may comprise a profile configured to facilitate rupture of the connector at the rupture area of the segment. The rupture may be at a designated area of the connector. The seam may comprise a line. The set of segments may be provided along the line. The line may comprise a tear line. The rupture may be at the seam. The rupture may be at the tear line. The connector may be configured to form a projection at deployment of the airbag. The projection may comprise a tab. The projection may be formed on the door. Each segment may be configured to form a generally uniform tab on the door at deployment of the airbag. The generally uniform tab of each segment may comprise a projection having substantially the same form at each segment. The generally uniform tab of each segment may comprise a projection having substantially the same size at each segment. The generally uniform tab of each segment may comprise a projection having substantially the same shape at each segment.
[0126] According to an exemplary embodiment as shown schematically in FIGURE 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H, 16A- 16H 23A-23F and 24A-24F, the panel BP may comprise a structural substrate SB; the structural substrate may comprise a molded substrate; the molded substrate may comprise an injection molded substrate; the base panel with the seam and the door may be integrally formed; the base panel with the seam and the door may be injection molded. See FIGURES 25, 30 and 31A-31C. According to an exemplary embodiment as shown schematically in FIGURE 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H, 16A-16H, 23A-23F. 24A-24F and 25, the structural substrate may be formed in an apparatus shown as mold ME; the base panel may be formed in an apparatus; the apparatus may comprise a mold; each segment may be formed in the base panel by a tool. The tool may comprise a slider arrangement; the slider arrangement may be configured to form the seam in the base panel; the slider arrangement may comprise a slider configured to form a connector at each segment; the slider arrangement of the apparatus may be configured to form a feature at each segment. The seam may comprise a weakening line. The seam may comprise a tear line. The structural substrate may be formed by a method. The base panel may be formed by a method. The method may comprise the steps of (a) forming the base panel and (b) forming a seam in the base panel to provide the door. The seam may be formed by a tool. The tool may comprise a slider arrangement. The step of forming the seam in the base panel may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a connector at each segment. The step of forming the set of segments in the base panel may comprise forming a feature at each segment. The step of forming the base panel may comprise injection molding a resin material to form the base panel. The component may comprise a hinge coupling the door to the base panel at deployment of the airbag.
[0127] According to an exemplary embodiment as shown schematically in FIGURES 7A-7F, the hinge HG may comprise reinforcement. The reinforcement may comprise fabric.
[0128] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H, 16A- 16H 23A-23F and 24A-24F, the set of segments SG may be configured to form a weakening line SP/TR at the seam of the base panel BP. The seam may comprise a weakening line in the base panel. The seam may comprise a weakening area. The seam may comprise a tear area. The seam may comprise a separating area. The seam may comprise a weakening area between the door and the base panel. Each segment may comprise a connector comprising a connecting material. The base may comprise a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of cavities in the rear side of the structural substrate. The set of cavities may comprise at least one cavity comprising a profile. Each segment may comprise a cavity. [0129] According to an exemplary embodiment as shown schematically in FIGURES 30 and 31A-31C, a method of producing a component configured for deployment of an airbag may comprise the steps of forming a base panel; and forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag. See also FIGURES 25, 26A-26D, 27A-27E. 28A-28D and 29A-29D. The seam may be formed by a tool. The step of forming the separation area in the base panel may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a connector at each segment. The tool may comprise a slider arrangement. The step of forming the separation area may comprise forming a seam in the base panel. The step of forming the seam may comprise forming a set of segments in the base panel. The step of forming the set of segments in the base panel may comprise forming a feature at each segment. The step of forming the set of segments in the base panel may comprise forming a connector comprising a feature at each segment. The step of forming the base panel may comprise injection molding a resin material to form the base panel. The door may comprise an airbag door with a hinge provided in the base panel. [0130] According to an exemplary embodiment as shown schematically in FIGURES 25, 26A-26D, 27A-27E. 28A-28D and 29A-29D, an apparatus for producing a component configured for deployment of an airbag may comprise a mold configured for forming a base panel and a tool configured for forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag; the tool may comprise a slider arrangement. The separation area may comprise a seam; the seam may comprise a set of segments. According to an exemplary embodiment as shown schematically in FIGURES 25, 26A-26D, 27A-27E, 28A-28D and 29A-29D, the slider arrangement SL may comprise a set of slider elements such as blades BL; the slider elements may comprise a set of blades; the slider elements may comprise elements of varying size and/or varying depth; the slider elements may comprise elements of varying shape; the slider elements may comprise elements of varying form.
[0131] According to an exemplary embodiment as shown schematically in FIGURES [0132] 25, 26A-26D, 27A-27E. 28A-28D and 29A-29D, the mold ML may comprise an injection mold; the mold may be configured to form the base panel from injection-molded resin NP. The tool MS may be configured to form a set of segments for the seam; each segment may comprise a feature; the feature may comprise a connector; the feature may comprise a gap.
[0133] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E and 7A-7F, a component C for a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate SB formed to a base panel BP. The structural substrate SB/BP may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line TR configured to provide a separation area SP for the opening for deployment of the airbag. The line may comprise a set of segments in the structural substrate; each segment of the set of segments may comprise a feature. The feature may be configured to facilitate formation of an opening in the structural substrate at the line for deployment of the airbag. The line may comprise a tear line. The line may comprise a separation line in the separation area. The separation area may comprise a separation line. The separation line may comprise a tear line. Each segment of the set of segments may comprise a connector. The connector may comprise a profile. The feature may comprise the connector. The feature may comprise a cavity. The cavity may be formed in the rear side of the structural substrate. The cavity may comprise a profile. The structural substrate may comprise a base comprising a base panel. The line may comprise a seam. At deployment of the airbag the base may be configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel. The seam may comprise the set of segments; each segment may comprise a connector of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening. The feature may comprise the connector. The front side of the panel may comprise a contoured surface. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The feature may comprise a notch. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate. The profile of the cavity may comprise a depth within the rear side of the structural substrate. The profile of the cavity may comprise a curved surface. The profile of the cavity may comprise a flat surface. The profile of the cavity may comprise a curved shape. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0134] According to an exemplary embodiment as shown schematically in FIGURES 5A-5C, 6A-6E, 7A-7G, 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H, a component for a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a separation area for the opening for deployment of the airbag. The separation area may comprise a set of gaps in the structural substrate. The set of gaps may comprise at least one gap comprising a profile. The separation area may comprise a line. The separation area may comprise a separation line. The separation line may comprise a tear line. The separation line may comprise a seam. The line may comprise a seam comprising a set of features. The set of features may comprise a set of connectors. The set of features may comprise the set of gaps and the set of connectors. The profile of the connector may comprise a curved surface. The profile of the connector may comprise a flat surface. The profile of the connector may comprise a tapered shape. The profile of the connector may comprise a curved shape. The seam may comprise the tear line. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate. The profile of the gap may comprise a curved surface. The profile of the gap may comprise a flat surface. The profile of the gap may comprise a curved shape. The gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side. The opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0135] According to an exemplary embodiment as shown schematically in FIGURES 2A- 2B, 3A-3D and 4A-4F, an airbag system for an interior of a vehicle configured for deployment of an airbag for an occupant of the vehicle upon an event may comprise (a) an airbag module ABM providing the airbag AB configured for deployment from the component C; and (b) a base of the component comprising a base panel BP with a seam SP/TR. See also FIGURES 5A-5C, 6A-6E, 7A-7G and 10A-10F. At deployment of the airbag the base may be configured to form a door ABD at the seam of the base panel to provide an opening for deployment of the airbag through the base panel. The seam may comprise a set of segments SG; each segment may comprise a connector CN of the door to the base panel. The connector of each segment may be configured to separate to facilitate formation of the opening; each segment may comprise a feature configured to facilitate formation of the opening for deployment of the airbag. See FIGURES 9A-9C, 10A-10F, 11A-11F, 12A-12F, 13A-13H, 14A-14H, 15A-15H and 16A-16H.
Exemplary Embodiments - B
[0136] According to an exemplary embodiment as shown schematically in the FIGURES, a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of cavities in the rear side of the structural substrate. The set of cavities may comprise at least one cavity comprising a profile. The front side of the panel may comprise a substantially planar surface opposite the at least one cavity. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of cavities in the rear side of the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of cavities in the rear side of the structural substrate. The profile of the cavity may comprise a depth within the rear side of the structural substrate. The profile of the cavity may comprise a curved surface. The profile of the cavity may comprise a flat surface. The profile of the cavity may comprise a curved shape. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The intermediate layer may comprise a foam configured to fill a least one notch in the front side of the structural substrate. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0137] According to an exemplary embodiment as shown schematically in the FIGURES, a component for a vehicle interior configured to facilitate deployment of an airbag may comprise a structural substrate. The structural substrate may comprise a rear side facing the airbag and a front side providing a surface. The rear side of the structural substrate may be configured for contact from the airbag to establish an opening for deployment of the airbag. The structural substrate may comprise a line configured to provide a tear line for the opening for deployment of the airbag. The line may comprise a set of gaps in the structural substrate. The set of gaps may comprise at least one gap comprising a profile. The tear line may comprise at least one of (a) a weakening line or (b) a weakened section. The line may comprise a set of notches in the front side of the structural substrate. The set of notches may comprise at least one notch comprising a profile. The set of notches in the front side of the structural substrate may be arranged adjacent the set of gaps in the structural substrate. The set of notches in the front side of the structural substrate may be offset from the set of gaps in the structural substrate. The profile of the gap may comprise a curved surface. The profile of the gap may comprise a flat surface. The profile of the gap may comprise a curved shape. The gap may comprise an opening in the rear side and an opening in the front side; the opening in the rear side may be larger than the opening in the front side. The opening in the rear side may be connected to the opening in the front side by at least one of (a) a curved surface; (b) an angled surface. The component may comprise a cover over the structural substrate. The cover may comprise an outer surface opposite the structural substrate comprising a generally uniform exterior surface. The outer surface may be configured so that the line is not readily perceptible at the outer surface. The component may comprise an intermediate layer between the cover and the structural substrate. The intermediate layer may comprise at least one of (a) a foam; (b) a textile. The structural substrate may comprise at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene. The rear side of the structural substrate may be configured to support an airbag module. The component may comprise at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
[0138] According to an exemplary embodiment as shown schematically in the FIGURES, the present invention relates to a vehicle interior component, a method for manufacturing said vehicle interior component and a mold to form said vehicle interior component. The component may comprise a trim component. The component may comprise a cover, an intermediate layer and a substrate. The cover may comprise an exterior cover layer. The intermediate layer may comprise a functional layer. The substrate may comprise an area configured to enable an airbag deployment. The area may comprise a structure configured to be a weakening of the substrate. The weakening may comprise a specific weakening structure. The design of the weakening structure is configured to be manufactured by injection molding process. An injection molding process and tool are disclosed. They are configured to manufacture the weakening structure formed in the substrate. The tool may comprise sliders. The method may comprise the sequence of the manufacturing steps. According to an exemplary embodiment, a method for use of the component may comprise closing the mold, injecting resin, moving slider(s), forming a substrate, demolding the substrate, foaming on the substrate (optional), and laminating a cover to the substrate.
Figure imgf000035_0001
[0139] It is important to note that the present inventions (e.g. inventive concepts, etc.) have been described in the specification and/or illustrated in the FIGURES of the present patent document according to exemplary embodiments; the embodiments of the present inventions are presented by way of example only and are not intended as a limitation on the scope of the present inventions. The construction and/or arrangement of the elements of the inventive concepts embodied in the present inventions as described in the specification and/or illustrated in the FIGURES is illustrative only. Although exemplary embodiments of the present inventions have been described in detail in the present patent document, a person of ordinary skill in the art will readily appreciate that equivalents, modifications, variations, etc. of the subject matter of the exemplary embodiments and alternative embodiments are possible and contemplated as being within the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. It should also be noted that various/other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be made in the configuration and/or arrangement of the exemplary embodiments (e.g. in concept, design, structure, apparatus, form, assembly, construction, means, function, system, process/method, steps, sequence of process/method steps, operation, operating conditions, performance, materials, composition, combination, etc.) without departing from the scope of the present inventions; all such subject matter (e.g. modifications, variations, embodiments, combinations, equivalents, etc.) is intended to be included within the scope of the present inventions. The scope of the present inventions is not intended to be limited to the subject matter (e.g. details, structure, functions, materials, acts, steps, sequence, system, result, etc.) described in the specification and/or illustrated in the FIGURES of the present patent document. It is contemplated that the claims of the present patent document will be construed properly to cover the complete scope of the subject matter of the present inventions (e.g. including any and all such modifications, variations, embodiments, combinations, equivalents, etc.); it is to be understood that the terminology used in the present patent document is for the purpose of providing a description of the subject matter of the exemplary embodiments rather than as a limitation on the scope of the present inventions.
[0140] It is also important to note that according to exemplary embodiments the present inventions may comprise conventional technology (e.g. as implemented and/or integrated in exemplary embodiments, modifications, variations, combinations, equivalents, etc.) or may comprise any other applicable technology (present and/or future) with suitability and/or capability to perform the functions and processes/operations described in the specification and/or illustrated in the FIGURES. All such technology (e.g. as implemented in embodiments, modifications, variations, combinations, equivalents, etc.) is considered to be within the scope of the present inventions of the present patent document.

Claims

CLAIMS The invention claimed is:
1. A component for a vehicle interior configured to facilitate deployment of an airbag comprising: a base comprising a base panel with a separation area; wherein at deployment of the airbag the base is configured to form a door at the separation area of the base panel to provide an opening for deployment of the airbag through the base panel; wherein the separation area comprises a set of segments; wherein each segment comprises a connector of the door to the base panel; wherein the connector of each segment is configured to separate to facilitate formation of the opening.
2. The component of Claim 1 wherein each segment comprises features configured to selectively locate a stress concentration for rupture at the separation area during deployment.
3. The component of Claim 1 wherein at deployment of the airbag the base is configured to form the door along the separation area of the base panel to provide the opening for deployment of the airbag through the base panel.
4. The component of Claim 1 wherein the separation area comprises a separation line.
5. The component of Claim 4 wherein the separation line comprises a seam.
6. The component of Claim 4 wherein the separation line comprises a tear line.
7. The component of Claim 1 wherein each segment comprises a connector between the door and the base panel.
8. The component of Claim 1 wherein each connector comprises a separation section; wherein the separation section comprises a rupture area.
9. The component of Claim 1 wherein each connector comprises a web of material.
10. The component of Claim 1 wherein each connector comprises a profile.
11. The component of Claim 1 wherein each segment comprises a feature.
12. The component of Claim 1 wherein each segment comprises the connector and a feature.
13. The component of Claim 12 wherein the feature comprises a feature adjacent to the connector.
14. The component of Claim 12 wherein the feature at the segment is configured to facilitate rupture of the connector at a rupture area of the segment.
15. The component of Claim 12 wherein the feature at the segment comprises at least one of a gap, groove, countergroove, tapering, multi-dimensional tapering, notch, countemotch, opening, aperture, cavity, rib, profile, shape, variation of width.
16. The component of Claim 12 wherein the feature at the segment comprises at least one of a gap and/or a groove and/or an opening.
17. The component of Claim 12 wherein the feature at the segment comprises at least one of a groove and/or a countergroove and/or a rib.
18. The component of Claim 12 wherein the feature at the segment comprises at least one of tapering of the connector and/or multi-dimensional tapering of the connector and/or variation of width of the connector and/or variation of height of the connector.
19. The component of Claim 12 wherein the feature at the segment comprises tapering of the connector.
20. The component of Claim 12 wherein the feature at the segment comprises multi-dimensional tapering of the connector.
21. The component of Claim 12 wherein the feature at the segment comprises variation of width and/or height of the connector.
22. The component of Claim 12 wherein the feature at the segment comprises at least one of variation of thickness of the connector and/or variation of shape of the connector.
23. The component of Claim 12 wherein the feature at the segment is configured to direct a stress concentration to a rupture area of the connector.
24. The component of Claim 23 wherein the stress concentration is sufficient to separate the door from the base panel at the rupture area.
25. The component of Claim 23 wherein the stress concentration is sufficient to rupture the seam of the base panel to form the door at the rupture area.
26. The component of Claim 1 wherein the connector comprises a trapezoidal shape.
27. The component of Claim 1 wherein the connector comprises a tapering shape.
28. The component of Claim 1 wherein the connector comprises a curved profile.
29. The component of Claim 1 wherein the connector comprises a sloped profile.
30. The component of Claim 1 wherein the connector comprises a thin section at the separation area at the base panel.
31. The component of Claim 1 wherein the separation area of the base panel is configured to comprise a relatively smooth separation surface after deployment of the airbag door.
32. The component of Claim 1 wherein the separation area is configured to comprise a relatively smooth rupture area.
33. The component of Claim 1 wherein at deployment the separation area is configured to comprise a reduced size of stress concentration area for rupture.
34. The component of Claim 1 wherein each segment comprises a section comprising a gap and a section comprising a connector.
35. The component of Claim 34 wherein the connector comprises a trapezoidal shape and the gap comprises an aperture in the base panel adjacent the connector.
36. The component of Claim 35 wherein the aperture comprises a shape comprising a middle portion between a first leg and a second leg.
37. The component of Claim 36 wherein a height of the trapezoidal shape of the connector is greater than a width of the middle portion of the aperture.
38. The component of Claim 36 wherein the aperture comprises an obtuse angle between the first leg and the middle portion.
39. The component of Claim 36 wherein the first leg comprises a length greater than a width of the middle portion.
40. The component of Claim 35 wherein the aperture comprises a concave polygon shape.
41. The component of Claim 40 wherein the concave polygon shape comprises more than six sides.
42. The component of Claim 1 wherein each section comprises a gap of a first distance and a section comprising a gap of a second distance and a connector comprising a tapering profile.
43. The component of Claim 1 wherein each segment comprises a bracket- shaped gap-
44. The component of Claim 1 wherein each segment comprises (a) a generally [ shaped gap; (b) a generally \_/ shaped gap; or (c) a generally U shaped gap.
45. The component of Claim 1 wherein each segment comprises a notch.
46. The component of Claim 1 wherein each connector comprises a tapered bridge.
47. The component of Claim 1 wherein the connector comprises a thin section at the separation area.
48. The component of Claim 1 wherein each segment is configured to form a separation surface at the opening in the base panel.
49. The component of Claim 1 wherein each segment is configured to form a projection at the airbag door.
50. The component of Claim 1 wherein the connector comprises a multidimensional profile.
51. The component of Claim 1 further comprising a continuous rib around the airbag door.
52. The component of Claim 1 wherein the connector comprises a profile configured to facilitate rupture of the connector at a rupture area of the segment.
53. The component of Claim 1 wherein the set of segments is provided along a line.
54. The component of Claim 1 wherein the connector is configured to form a projection at deployment of the airbag.
55. The component of Claim 1 wherein the projection is formed on the door.
56. The component of Claim 1 wherein each segment is configured to form a generally uniform tab on the door at deployment of the airbag; wherein the generally uniform tab of each segment comprises a projection having substantially the same form at each segment.
57. The component of Claim 1 wherein the panel comprises a structural substrate.
58. The component of Claim 57 wherein the structural substrate comprises an injection molded substrate.
59. The component of Claim 57 wherein the structural substrate is formed in an apparatus; wherein the apparatus comprises a mold.
60. The component of Claim 1 wherein each segment is formed in the base panel by a tool; wherein the tool comprises a slider arrangement.
61. The component of Claim 60 wherein the slider arrangement comprises a slider configured to form a connector at each segment.
62. The component of Claim 60 wherein the slider arrangement is configured to form a feature at each segment.
63. The component of Claim 1 wherein the base panel is formed by a method; wherein the method comprises the steps of (a) forming the base panel and (b) forming a seam in the base panel to provide the door; wherein the seam is formed by a tool; wherein the step of forming the seam in the base panel comprises forming a set of segments in the base panel.
64. A method of producing a component configured for deployment of an airbag comprising the steps of:
(a) forming a base panel;
(b) forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag; wherein the seam is formed by a tool; wherein the step of forming the separation area in the base panel comprises forming a set of segments in the base panel; wherein the step of forming the set of segments in the base panel comprises forming a connector at each segment.
65. The component of Claim 64 wherein the tool comprises a slider arrangement.
66. The component of Claim 64 wherein the step of forming the separation area comprises forming a seam in the base panel; wherein the step of forming the seam comprises forming a set of segments in the base panel.
67. The component of Claim 64 wherein the step of forming the set of segments in the base panel comprises forming a feature at each segment.
68. The component of Claim 64 wherein the step of forming the set of segments in the base panel comprises forming a connector at each segment.
69. The component of Claim 64 wherein the step of forming the base panel comprises injection molding a resin material to form the base panel.
70. An apparatus for producing a component configured for deployment of an airbag comprising: a mold configured for forming a base panel; a tool configured for forming a separation area in the base panel to provide a door configured to be formed upon deployment of the airbag; wherein the tool comprises a slider arrangement.
71. The apparatus of Claim 70 wherein the slider arrangement comprises a set of slider elements.
72. The apparatus of Claim 71 wherein the slider elements comprise elements of varying shape and/or varying form.
73. The apparatus of Claim 70 wherein the mold comprises an injection mold; wherein the mold is configured to form the base panel from injection-molded resin.
74. The apparatus of Claim 70 wherein the tool is configured to form a set of segments for a seam.
75. The apparatus of Claim 74 wherein each segment comprises a feature; wherein the feature comprises a connector and/or a gap.
76. A component for a vehicle interior configured to facilitate deployment of an airbag comprising: a structural substrate; wherein the structural substrate comprises a rear side facing the airbag and a front side providing a surface; wherein the rear side of the structural substrate is configured for contact from the airbag to establish an opening for deployment of the airbag; wherein the structural substrate comprises a line configured to provide a separation area for the opening for deployment of the airbag; wherein the line comprises a set of segments in the structural substrate; wherein each segment of the set of segments comprises a feature; wherein the feature is configured to facilitate formation of an opening in the structural substrate at the line for deployment of the airbag.
77. The component of Claim 76 wherein the line comprises a separation line in the separation area; wherein the separation line comprises a tear line.
78. The component of Claim 76 wherein each segment of the set of segments comprises a connector; wherein the connector comprises a profile.
79. The component of Claim 78 wherein the feature comprises the connector.
80. The component of Claim 76 wherein the feature comprises a cavity.
81. The component of Claim 76 further comprising a cover over the structural substrate; wherein the cover comprises an outer surface opposite the structural substrate comprising a generally uniform exterior surface; wherein the outer surface is configured so that the line is not readily perceptible at the outer surface.
82. The component of Claim 81 further comprising an intermediate layer between the cover and the structural substrate; wherein the intermediate layer comprises at least one of (a) a foam; (b) a textile.
83. The component of Claim 76 wherein the structural substrate comprises at least one of (a) a resin; (b) a thermoplastic resin; (c) polypropylene; (d) reinforced polypropylene; (e) fiber reinforced polypropylene; (f) glass fiber reinforced polypropylene.
84. The component of Claim 76 comprising at least one of (a) a trim panel; (b) an instrument panel; (c) a door panel; (d) a pillar.
85. A component for a vehicle interior configured to facilitate deployment of an airbag comprising: a structural substrate; wherein the structural substrate comprises a rear side facing the airbag and a front side providing a surface; wherein the rear side of the structural substrate is configured for contact from the airbag to establish an opening for deployment of the airbag; wherein the structural substrate comprises a separation area for the opening for deployment of the airbag; wherein the separation area comprises a set of gaps in the structural substrate; wherein the set of gaps comprises at least one gap comprising a profile.
86. The component of Claim 85 wherein the separation area comprises a separation line.
87. The component of Claim 85 wherein the set of features comprises the set of gaps and a set of connectors.
88. An airbag system for an interior of a vehicle configured for deployment of an airbag for an occupant of the vehicle upon an event comprising:
(a) an airbag module providing the airbag configured for deployment from the component;
(b) a base of the component comprising a base panel with a seam; wherein at deployment of the airbag the base is configured to form a door at the seam of the base panel to provide an opening for deployment of the airbag through the base panel; wherein the seam comprises a set of segments; wherein each segment comprises a connector of the door to the base panel; wherein the connector of each segment is configured to separate to facilitate formation of the opening.
89. The system of Claim 88 wherein each segment comprises a feature configured to facilitate formation of the opening for deployment of the airbag.
PCT/US2023/011784 2022-01-28 2023-01-27 Component for vehicle interior WO2023147086A2 (en)

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US63/304,414 2022-01-28

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7100941B2 (en) * 2003-02-24 2006-09-05 Collins & Aikman Pre-weakening of fabric covered airbag doors
US8899616B2 (en) * 2008-12-23 2014-12-02 Johnson Controls Technology Company Airbag deployment control system
EP2783923B1 (en) * 2013-03-28 2016-05-18 Volvo Car Corporation Airbag housing assembly
KR20150139740A (en) * 2014-06-04 2015-12-14 현대모비스 주식회사 Air bag module
KR101776466B1 (en) * 2016-03-15 2017-09-07 현대자동차주식회사 Crash pad for vehicle and manufacturing method of the same
GB2570456B (en) * 2018-01-24 2020-06-17 Ford Global Tech Llc Vehicle trim panel
US11097682B2 (en) * 2019-11-22 2021-08-24 GM Global Technology Operations LLC Airbag chute assembly

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