Instrument panel with passenger airbag

Abstract

The present disclosure provides for a "dashboard with passenger airbag." A dashboard includes a housing and an airbag. The housing includes a slot elongated to an end and a door at least partially covering the end of the slot. The airbag is disposed in the slot. The housing includes a first ridge elongated along a perimeter of the end of the slot and a second ridge elongated along a perimeter of the door.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to vehicle airbags. BACKGROUND

[0002] Vehicles are equipped with airbags. In the event of a collision, an inflator activates and provides inflation medium to the airbag, and the airbag is pressurized during the collision and acts as a cushion for the occupant. Airbags are located at various fixed positions in the passenger compartment of the vehicle. Vehicles typically include a driver airbag mounted in the steering wheel, a passenger airbag mounted in the instrument panel in the vehicle forward direction of the front passenger seat, and a side curtain airbag mounted in the roof rail. SUMMARY

[0003] An instrument panel includes a housing including a slot elongated to an end and a door at least partially covering the end of the slot, and an airbag disposed in the slot. The housing includes a first ridge elongated along a perimeter of the end of the slot and a second ridge elongated along a perimeter of the door.

[0004] The housing can include a hinge connecting the door and the slot and elongated along the perimeter of the end of the slot. The hinge can have an S-shaped cross-section.

[0005] The first ridge can be elongated along more than half of the perimeter of the end of the slot, and the second ridge can be elongated along more than half of the perimeter of the door.

[0006] The door and the end of the slot can define a gap therebetween. The gap can have a substantially constant width along the perimeter of the end of the slot.

[0007] The housing can include a hinge connecting the door and the slot, and the hinge and the gap combined can be elongated along substantially the entire perimeter of the end of the slot.

[0008] The first ridge and the second ridge can be elongated along substantially the entire gap. The first ridge can be elongated along the gap from a first end beyond the gap to a second end beyond the gap, and the second ridge can be elongated along the gap from a first end beyond the gap to a second end beyond the gap. The first end of the first ridge can be closer to the first end than the second end of the second ridge; the second end of the first ridge can be closer to the second end than the first end of the second ridge; the first end of the first ridge can be offset along the perimeter of the end of the runner from the first end of the second ridge; and the second end of the first ridge is offset along the perimeter from the second end of the second ridge.

[0009] The gap can be elongated from a first end to a second end; the first end of the first ridge and the first end of the second ridge can be curved around the first end of the gap; and the second end of the first ridge and the second end of the second ridge can be curved around the second end of the gap.

[0010] The first end of the first ridge and the first end of the second ridge can be in contact with each other, and the second end of the first ridge and the second end of the second ridge can be in contact with each other.

[0011] The instrument panel can further include a substrate; and the housing can be attached to the substrate; and the substrate includes a slot elongated along the gap.

[0012] The housing can be a single piece.

[0013] The housing can include a flange extending outwardly from the runner. The instrument panel can further include a substrate, and the door and the flange can be attached to the substrate.

[0014] The instrument panel can further include a substrate, and the housing can be attached to the substrate. The housing can be friction welded to the substrate.

[0015] The instrument panel can further include a cover and a foam layer between the substrate and the cover; and the substrate can have an outer surface and an inner surface; and the housing can be attached to the inner surface. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 is a top view of a passenger compartment of a vehicle.

[0017] Figure 2 is an exploded perspective view of an instrument panel of the passenger compartment of Figure 1 is an exploded perspective view of an instrument panel of the passenger compartment of

[0018] Figure 3 is Figure 2 a cross-sectional view of the instrument panel with the airbag in an uninflated position.

[0019] Figure 4 is Figure 2 a cross-sectional view of the instrument panel with the airbag in an inflated position.

[0020] Figure 5 is Figure 2 a plan view of a portion of the housing of the instrument panel. DETAILED DESCRIPTION

[0021] Referring to the drawings, an instrument panel 32 in a vehicle 30 includes a housing 56 and an airbag 66. The housing 56 includes a channel 44 that extends to an end 46 and a door 58 that at least partially covers the end 46 of the channel 44. The airbag 66 is disposed in the channel 44. The housing 56 includes a first ridge 72 that extends along a perimeter of the end 46 of the channel 44 and a second ridge 74 that extends along a perimeter of the door 58. (The adjectives“first” and“second” are used as identifiers throughout this document and are not intended to indicate importance or order.)

[0022] The instrument panel 32 can be a foam-in-place instrument panel, and the design of the instrument panel 32 allows for the channel 44 to be installed from the bottom up. The channel 44 allows for a larger airbag 66 in both the lateral and longitudinal directions compared to other designs while still deploying the airbag 66 quickly and smoothly along the score line 94 of the cover 40. Installing from the bottom up allows the walls of the channel 44 to be thicker and stiffer, which concentrates the forces of the airbag 66 on the door 58 during inflation. With the concentration of the inflation forces from the airbag 66, the instrument panel 32 experiences reduced foam breakage, more consistent opening of the instrument panel 32, improved turtle necking, and design freedom in using any of a variety of types of scoring techniques on the cover 40.

[0023] Referring to Figure 1 , the vehicle 30 includes a passenger compartment 47 to accommodate occupants of the vehicle 30, if any. The passenger compartment 47 includes a driver seat 48 and a passenger seat 50 disposed forward of the passenger compartment 47 and one or more rear seats 52 disposed rearward of the driver seat 48 and the passenger seat 50. The passenger compartment 47 can also include a third row of seats (not shown) at a rear of the passenger compartment 47. In Figure 1 , the driver seat 48 and the passenger seat 50 are shown as bucket seats, but the seats 48, 50, 52 can also be other types. The position and orientation of the seats 48, 50, 52 and components thereof can be adjusted by the occupants.

[0024] The instrument panel 32 may be located at the front of the passenger compartment 47 and face the driver's seat 48 and passenger seat 50. The instrument panel 32 may include vehicle controls such as a steering wheel; instruments, dials and information displays; heating and ventilation equipment; radio and other electronic devices; etc. As described below, the instrument panel 32 may be a body foam instrument panel, that is, an instrument panel assembled by injection molding a foam layer 42 between a substrate 34 and a cover 40.

[0025] refer to Figure 2 and Figure 3 The instrument panel 32 includes a base plate 34. The base plate 34 extends laterally (i.e., in the vehicle's lateral direction) across the passenger compartment 47 and is curved longitudinally (i.e., in the vehicle's forward direction). The outer surface 36 of the base plate 34 faces the passenger compartment 47, while the inner surface 38 faces away from the passenger compartment 47. The outer surface 36 is the concave side of the base plate 34, while the inner surface 38 is the convex side of the base plate 34. The base plate 34 may be a plastic and / or composite material, such as glass-filled polypropylene.

[0026] The substrate 34 includes a slot 54. The slot 54 may be U-shaped; more specifically, a portion of the slot 54 may extend laterally, and two portions may extend longitudinally (i.e., in the vehicle's forward direction) from the ends of the laterally extended portion of the slot 54. The slot 54 may have a constant width along its length. The substrate 34 may include a notch 92 extending between the ends of the slot 54. The notch 92 may be a weakened region, for example, with a thickness less than that of the surrounding region. The notch 92 may be formed during the injection molding of the substrate 34, or the notch 92 may be formed by laser weakening a portion of the substrate 34 after the substrate has been formed.

[0027] A foam layer 42 is disposed between the substrate 34 (e.g., outer surface 36) and the cover 40. The foam layer 42 may be, for example, polyurethane with a foam-like structure (i.e., with empty cells dispersed throughout).

[0028] Cover 40 extends over the outer surface 36 of substrate 34 and over foam layer 42. Cover 40 may be an aesthetically pleasing material for the occupants, such as leather. Cover 40 may include serrated lines 94, i.e., weakened areas that will be opened due to airbag 66 inflation.

[0029] The housing 56 includes a slide 44, a door 58, a hinge 60 connecting the door 58 to the slide 44, and a flange 62. The housing 56 can be integral, i.e., it can be a single piece, i.e., it can be made of a single piece of homogeneous material without seams, joints, fasteners, or adhesives holding the housing 56 together. The housing 56 can be positioned in front of the passenger seat 50, i.e., in the forward direction of the passenger seat 50.

[0030] The slide 44 has a tubular shape and extends from the bottom panel 64 to the end 46. The slide 44 may have a rectangular cross-sectional shape, for example, with rounded corners. The bottom panel 64 may be closed, while the end 46 may be open. The inner transverse cross-sectional width of the slide 44 may be approximately equal to the transverse length of the slot 54, and the inner longitudinal cross-sectional width of the slide 44 may be approximately equal to the longitudinal length of the slot 54. The outer transverse cross-sectional width of the slide 44 may be longer than the transverse length of the slot 54, and the outer longitudinal cross-sectional width of the slide 44 may be longer than the longitudinal length of the slot 54. Furthermore, the slide 44 may include a reinforcement 90 extending from the bottom panel 64 to the end 46, and the reinforcement 90 further extends beyond the transverse and longitudinal lengths of the slot 54. At least some of the periphery of the end 46 of the slide 44 extends along the slot 54. The slot 54 (e.g., the entire length of the slot 54) extends along the periphery of the end 46 of the slide 44. The slot 54 can extend away from the hinge 60 along the periphery of the end 46 of the slide 44.

[0031] Airbag 66 is disposed in slide 44. Airbag 66 may be a passenger airbag. The size of airbag 66 may be designed to cushion the occupant of passenger seat 50 during a frontal collision of vehicle 30. Airbag 66 may be in an uninflated position (e.g., Figure 3 Inflate to the inflation position (as shown in the image) Figure 4 (as shown in the image).

[0032] Flange 62 extends outward from groove 44. Specifically, flange 62 extends outward from the periphery of end 46. Flange 62 faces substrate 34 and can be shaped to conform to substrate 34.

[0033] Door 58 at least partially covers the end 46 of the slide 44. Door 58 is adjacent to the substrate 34. One side of door 58 faces the substrate 34, while the other side of door 58 faces the airbag 66.

[0034] Hinge 60 connects door 58 to end 46 of track 44. Hinge 60 extends along some periphery of end 46 of track 44; for example, hinge 60 may extend along a portion of periphery of end 46 of track 44, along which slot 54 does not extend. Hinge 60 may extend along notch 92. Hinge 60 may connect to the vehicle-facing edge of door 58. Hinge 60 has an S-shaped cross-section, i.e., a cross-section following at least two curves rotating in opposite directions, i.e., a cross-section following at least two curves (where the concave sides face opposite directions).

[0035] The end 46 of the door 58 and the slide 44 defines a gap 68 therebetween. The gap 68 can extend along the periphery of the end 46 of the slide 44. The gap 68 can extend along substantially the entire length of the slide 54. The hinge 60 and the gap 68 together can extend along substantially the entire periphery of the end 46 of the slide 44. The gap 68 can have a substantially constant width along its length.

[0036] The housing 56 is attached to the substrate 34. For example, flange 62 and / or door 58 are attached to the inner surface 38 of the substrate 34. Flange 62 and / or door 58 can be directly attached to the substrate 34 by any suitable means (e.g., adhesion, fastening, welding, etc.). For example, flange 62 and / or door 58 can be friction-welded to the inner surface 38 of the substrate 34, i.e., the boundaries between the substrate 34 and flange 62 and / or between the substrate 34 and door 58 can be fused together, such that molecules mix at the boundaries. Flange 62 and / or door 58 may include ribs 88 at which friction welding occurs. Groove 44 can be attached (e.g., friction-welded) to the substrate 34 via flange 62 and / or door 58.

[0037] refer to Figure 2 and Figure 5 The housing 56 includes a first ridge 72 extending along the periphery of an end 46 of the groove 44. The first ridge 72 extends from the end 46 of the groove 44 toward the substrate 34 and may extend beyond the substrate. The first ridge 72 may extend more than halfway along the periphery of the end 46 of the groove 44 and along substantially the entire gap 68 and the entire slot 54. The first ridge 72 extends from a first end 76 beyond the gap 68 to a second end 78 beyond the gap 68; in other words, the first ridge 72 is at least slightly longer than the gap 68.

[0038] The housing 56 includes a second ridge 74 extending along the periphery of the door 58. The second ridge 74 extends from the door 58 toward the substrate 34. The second ridge 74 may extend more than halfway along the periphery of the door 58 and along substantially the entire gap 68 and the entire slot 54. The second ridge 74 extends from a first end 80 beyond the gap 68 to a second end 82 beyond the gap 68; in other words, the second ridge 74 is at least slightly longer than the gap 68. Ribs 72 and 74 help prevent foam and other debris from entering the gap 68.

[0039] The first end 76 of the first ridge 72 is closer to the first end 80 than the second end 82 of the second ridge 74, and the second end 78 of the first ridge 72 is closer to the second end 82 than the first end 80 of the second ridge 74; in other words, the first ends 76 and 80 of ridges 72 and 74 are adjacent to each other, and the second ends 78 and 82 of ridges 72 and 74 are adjacent to each other. The first ends 76 and 80 can contact each other, and the second ends 78 and 82 can contact each other, thereby preventing the foam layer 42 from intruding into the gap 68 during assembly. The gap 68 extends from the first end 84 to the second end 86, and the first ends 76 and 80 of ridges 72 and 74 are adjacent to the first end 84 of the gap 68, while the second ends 78 and 82 of ridges 72 and 74 are adjacent to the second end 86 of the gap 68.

[0040] The first end 76 of the first ridge 72 and the first end 80 of the second ridge 74 bend around the first end 84 of the gap 68, and the second end 78 of the first ridge 72 and the second end 82 of the second ridge 74 bend around the second end 86 of the gap 68. The first end 76 of the first ridge 72 deviates from the first end 80 of the second ridge 74 along the periphery of the end 46 of the groove 44, and the second end 78 of the first ridge 72 deviates from the second end 82 of the second ridge 74 along the periphery. The first ridge 72 may be longer than the second ridge 74.

[0041] refer to Figure 4 In the event of a collision, for example, involving vehicle 30, airbag 66 inflates. When airbag 66 inflates, it presses against the slide rail 44 and door 58. The rigidity of the slide rail 44 concentrates the force of airbag 66 onto door 58. The S-shaped cross-section of hinge 60 allows hinge 60 to bend and door 58 to rotate open relative to slide rail 44. The offset of the first ends 76, 80 and the second ends 78, 82 of ridges 72, 74 allows door 58 to open without bending or breaking through ridges 72, 74, which are wider than the width of door 58. Door 58 breaks through foam layer 42 and covering 40, and airbag 66 inflates in front of the occupant of passenger seat 50. Airbag 66 cushions the occupant and can reduce injury.

[0042] This disclosure has been described in an illustrative manner, and it should be understood that the terminology used is intended to be descriptive rather than restrictive. In view of the foregoing teachings, many modifications and variations of this disclosure are possible, and this disclosure may be practiced in ways other than those specifically described.

[0043] According to the present invention, an instrument panel is provided, the instrument panel having: a housing including a groove extending to an end and a door at least partially covering the end of the groove; and an airbag disposed in the groove; wherein the housing includes a first ridge extending along the periphery of the end of the groove and a second ridge extending along the periphery of the door.

[0044] According to one embodiment, the housing includes a hinge that connects the door and the slide and extends along the periphery of the end of the slide.

[0045] According to one embodiment, the hinge has an S-shaped cross-section.

[0046] According to one embodiment, the first ridge extends more than half of the periphery of the end of the groove, and the second ridge extends more than half of the periphery of the door.

[0047] According to one embodiment, the ends of the door and the slide define a gap therebetween.

[0048] According to one embodiment, the gap has a substantially constant width along the periphery of the end of the groove.

[0049] According to one embodiment, the housing includes a hinge connecting the door and the slide, and the hinge and the clearance together extend substantially throughout the periphery along the end of the slide.

[0050] According to one embodiment, the first ridge and the second ridge extend substantially throughout the entire gap.

[0051] According to one embodiment, the first ridge extends along the gap from a first end beyond the gap to a second end beyond the gap, and the second ridge extends along the gap from the first end beyond the gap to a second end beyond the gap.

[0052] According to one embodiment, the first end of the first ridge is closer to the first end than the second end of the second ridge, the second end of the first ridge is closer to the second end than the first end of the second ridge, the first end of the first ridge is offset from the first end of the second ridge along the periphery of the end of the groove, and the second end of the first ridge is offset from the second end of the second ridge along the periphery.

[0053] According to one embodiment, the gap extends from a first end to a second end, the first end of the first ridge and the first end of the second ridge bend around the first end of the gap, and the second end of the first ridge and the second end of the second ridge bend around the second end of the gap.

[0054] According to one embodiment, the first end of the first ridge and the first end of the second ridge are in contact with each other, and the second end of the first ridge and the second end of the second ridge are in contact with each other.

[0055] According to one embodiment, the invention is further characterized by a substrate, wherein the housing is attached to the substrate, and the substrate includes a slot extending along the gap.

[0056] According to one embodiment, the housing is a single piece.

[0057] According to one embodiment, the housing includes a flange extending outward from the groove.

[0058] According to one embodiment, the invention is further characterized by a substrate, wherein the door and the flange are attached to the substrate.

[0059] According to one embodiment, the invention is further characterized by a substrate, wherein the housing is attached to the substrate.

[0060] According to one embodiment, the housing is friction-welded to the substrate.

[0061] According to one embodiment, the invention is further characterized by a cover and a foam layer between the substrate and the cover, wherein the substrate has an outer surface and an inner surface, and the housing is attached to the inner surface.

Claims

1. A dashboard comprising: A housing comprising a groove extending to an end and a door at least partially covering the end of the groove; as well as An airbag, which is disposed in the groove; The housing includes a first ridge extending along the periphery of the end of the slide and a second ridge extending along the periphery of the door; The end of the slide and the door define a gap therebetween; The first ridge and the second ridge extend substantially throughout the entire gap; The first ridge extends along the gap from a first end beyond the gap to a second end beyond the gap, and the second ridge extends along the gap from the first end beyond the gap to a second end beyond the gap.

2. The dashboard of claim 1, wherein the housing includes a hinge that connects the door and the slide and extends along the periphery of the end of the slide.

3. The dashboard of claim 1, wherein the first ridge extends more than half of the periphery of the end of the slide, and the second ridge extends more than half of the periphery of the door.

4. The dashboard of claim 2, wherein the hinge has an S-shaped cross-section.

5. The instrument panel of claim 1, wherein the gap has a substantially constant width along the periphery of the end of the slide.

6. The dashboard of claim 1, wherein the housing includes a hinge connecting the door and the slide, and the hinge and the clearance together extend substantially throughout the periphery of the end of the slide.

7. The instrument panel of claim 1, wherein the housing includes a flange extending outwardly from the slide.

8. The instrument panel of claim 7, further comprising a substrate, wherein the door and the flange are attached to the substrate.

9. The dashboard of claim 1, wherein the first end of the first ridge is closer to the first end of the second ridge than the second end of the second ridge, the second end of the first ridge is closer to the second end of the second ridge than the first end of the second ridge, the first end of the first ridge is offset from the first end of the second ridge along the periphery of the end of the slide, and the second end of the first ridge is offset from the second end of the second ridge along the periphery.

10. The instrument panel of claim 1, wherein the gap extends from a first end to a second end, the first end of the first ridge and the first end of the second ridge bend around the first end of the gap, and the second end of the first ridge and the second end of the second ridge bend around the second end of the gap.

11. The dashboard of claim 1, wherein the first end of the first ridge and the first end of the second ridge are in contact with each other, and the second end of the first ridge and the second end of the second ridge are in contact with each other.

12. The instrument panel of claim 1, further comprising a substrate, wherein the housing is attached to the substrate, and the substrate includes a slot extending along the gap.

13. The instrument panel of claim 1, wherein the housing is a single piece.

14. The instrument panel of claim 1, further comprising a substrate, wherein the housing is attached to the substrate.

15. The instrument panel of claim 14, further comprising a cover and a foam layer between the substrate and the cover, wherein the substrate has an outer surface and an inner surface, and the housing is attached to the inner surface.

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