Vehicle interior trimming panel

Abstract

A vehicle interior trim panel having an airbag mesh with a strategically configured reinforcement fold is provided. The vehicle interior panel includes an airbag cover configured to cover a deployable airbag and an adjacent panel portion positioned adjacent the airbag cover. The trim panel includes an airbag mesh having a hinge formed between a first mesh segment on a first side of the hinge and a second mesh segment on an opposite second side of the hinge. The first web segment is coupled to the adjacent panel portion and the second web segment is coupled to the airbag cover. The airbag net includes a reinforcement fold that extends through the hinge from the first net segment to the second net segment.

Description

Technical Field

[0001] The present disclosure relates generally to vehicle interior components and, more particularly, to a panel positioned over an air bag designed to deploy through the panel. Background Art

[0002] Personal motor vehicles are often equipped with airbags that are configured to inflate rapidly inside the passenger compartment of the vehicle in the event of a severe vehicle collision. Due to the nature of such collisions, airbags are designed to go from a folded state hidden behind a vehicle interior panel to a fully inflated state in less than one tenth of a second. During this short period of time, the airbag must also typically penetrate the overlying interior panel, which is typically a padded plastic sheet. Such panels are carefully designed to rupture in a controlled manner so that the airbag is obstructed as little as possible and so that the overlying panel does not rupture into multiple pieces during deployment.

[0003] The airbag net can be used to help selectively control the formation of the airbag cover from the exterior of the interior panel when the airbag is deployed. The airbag net helps form a hinge between the airbag cover and an adjacent or adjacent panel portion. To reinforce the hinge, multiple layers of airbag net can be used and folds can be incorporated along the main hinge portion. For example, EP2558335 B1 to Audi and Faurecia Innenraum Systeme shows a folded reinforcement along the length of the hinge. However, more selectively locating the reinforcement areas can help minimize costs and provide enhanced structural integrity relative to the airbag cover in other areas. Summary of the invention

[0004] According to various embodiments, a vehicle interior panel includes an airbag cover configured to cover a deployable airbag and an adjacent panel portion positioned adjacent to the airbag cover. The interior panel includes an airbag net having a hinge formed between a first net segment located on a first side of the hinge and a second net segment located on an opposite second side of the hinge. The first net segment is coupled to the adjacent panel portion and the second net segment is coupled to the airbag cover. The airbag net includes a reinforcing fold extending through the hinge from the first net segment to the second net segment.

[0005] In various embodiments, the reinforced fold has at least three overlapping layers.

[0006] In various embodiments, the reinforcing fold has an S-shaped cross-section.

[0007] In various embodiments, the reinforcement fold has two sections, each section having at least three overlapping layers.

[0008] In various embodiments, the reinforcing fold has an Ω-shaped cross-section.

[0009] In various embodiments, each of the first web segment and the second web segment is a single layer of airbag web.

[0010] In various embodiments, the airbag net has a first side, a second side, a third side, and a fourth side, and wherein the third side is an end of the first net segment and the fourth side is an end of the second net segment.

[0011] In various embodiments, the hinge extends completely from the first side edge to the second side edge.

[0012] In various embodiments, the reinforcement fold extends completely from the third side edge to the fourth side edge.

[0013] In various embodiments, there is a central portion between the first side and the second side, wherein the central portion includes a center point between the first side and the second side, and a length of the central portion between the first side and the second side is less than 50% of the total distance between the first side and the second side.

[0014] In various embodiments, the reinforcement fold is positioned entirely within the central portion.

[0015] In various embodiments, the first side and the second side are configured to extend at least partially along an X-direction relative to the vehicle.

[0016] In various embodiments, the longest extent of the reinforcement fold is configured to extend at least partially in the X-direction relative to the vehicle.

[0017] In various embodiments, the hinge is a fold that angles the first web segment relative to the second web segment.

[0018] In various embodiments, the reinforcement fold is located along an initial impact region where the deployable airbag is configured to make initial contact with the airbag cover.

[0019] It is contemplated that any number of the individual features of the above-described embodiments and any other embodiments depicted in the following drawings or description may be combined in any combination to define the invention, except where the features are incompatible. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Exemplary embodiments will be described below with reference to the following drawings, wherein like numerals represent like elements, and wherein:

[0021] Figure 1An exemplary vehicle interior trim panel having an airbag cover according to one embodiment is shown;

[0022] Figure 2 yes Figure 1 A cross-sectional view of a panel;

[0023] Figure 3 According to one embodiment, Figure 1 Airbag nets for vehicle interior panels;

[0024] Figure 4 yes Figure 3 A cross-sectional view of an airbag net;

[0025] Figure 5 is a graph showing an example of airbag test results showing a trend towards greater opening force in a cover center region as compared to a lateral cover side of the airbag cover, the greater opening force being presented as a pulse with a +Z direction displacement;

[0026] Figure 6 An airbag net according to another embodiment is shown; and

[0027] Figure 7 yes Figure 6 Cross-sectional view of the airbag net. DETAILED DESCRIPTION

[0028] Described below is a vehicle interior panel having an airbag cover and airbag net molded in to help selectively control the formation of the cover during airbag deployment. The airbag net has a reinforcing fold that extends in the direction of stretch and is more strategically positioned to handle the airbag cover opening forces. As opposed to a fold located at or aligned with a hinge, the reinforcing fold of the airbag net of the present invention extends along a center portion transverse to the hinge to help increase the structural integrity where the stress of the airbag is initially located. The panels described in the present disclosure eliminate the need for an entire double layer of net and can be quickly implemented with minimal adjustments to the overall manufacturing process of the panel. In addition, these arrangements can be more cost-effective and conserve material usage compared to existing reinforcement solutions.

[0029] Figure 1A vehicle interior panel 10, such as an instrument panel, is schematically illustrated and is manufactured for installation along a front end of a vehicle passenger compartment 12 and spans at least a portion (e.g., 40% to 100%) of the lateral width of the passenger compartment. When installed in a vehicle 14, the panel 10 overlies an airbag module 16 that is configured to inflate the airbag in the event of a vehicle collision. The panel 10 may include a decorative trim layer 18 (e.g., a foam-backed TPU layer or a spacer fabric-backed leather) that covers at least the illustrated portion of the panel when installed in the vehicle 14.

[0030] like Figure 2 and Figure 3 As shown, the panel 10 has a substrate 20 in which an airbag cover 22 is formed, wherein the airbag cover 22 is located adjacent to an adjacent panel portion 24. The substrate 20 is typically molded from a polymer-based material, such as a mineral reinforced polyolefin, a polycarbonate alloy, a thermoplastic elastomer (TPE), or a thermoplastic olefin (TPO). The airbag cover 14 is a molded-in feature of the panel 10, which means that the airbag door is formed in the same mold cavity with the adjacent panel portion 24 and is formed as a continuous piece from the same material. The adjacent panel portion 24 can be another portion of the substrate 20 as shown, a portion of the airbag module, etc., as long as it is directly or indirectly outside the boundaries of the airbag cover 22.

[0031] The airbag cover 22 has a perimeter 26 that at least partially defines a deployment opening through which the underlying airbag is deployed into the passenger compartment 12. In the case of an instrument panel, the substrate 20 is embodied as a portion of the molded panel 10 that is external to and surrounds the airbag cover 22. These teachings also apply to interior panels in the form of drop-in or back-side airbag chute assemblies having a frame that is configured for attachment to the instrument panel at a deployment opening formed through the panel. Door panels, roof panels, steering wheel panels, knee adjacent panels, and seat panels are some other non-limiting examples of applicable interior panels.

[0032] The airbag cover 22 may have one or more channels or perforations 28 extending completely or partially into the substrate 20. The channels 28 generally extend around the perimeter 26 to help control the strategic opening of the cover 22 during deployment of the airbag 30. The channels 28 extend only partially around the airbag cover 22, leaving a hinge area 32. In the illustrated embodiment, the airbag cover 22 is U-shaped with a U-shaped tear seam, as shown by the configuration of the channels 28. However, the illustrated configuration and shape of the panel 10 are non-limiting. For example, there may be no pre-weakening in the substrate 20, or the pre-weakening may be formed by a series of through openings in the substrate 20, a series of laser-formed blind holes, or any other suitable features that cause the substrate to split along the feature to form the airbag cover 22. The substrate 20 may also be configured to split along the hinge area 32, but may include a tether that anchors the airbag cover 22 to the adjacent panel portion 24 at the hinge. Different tear seam shapes are possible, such as H-shaped, X-shaped, Y-shaped, or curved. For example, an X-shaped tear seam can be used to form four triangular airbag covers with their apex located at the center of the X. One or more layers of the decorative trim layer 18 can also include a tear seam.

[0033] The airbag cover 22 has an outer surface that is generally in the same plane or along the same contour as the adjacent panel portion 24 of the substrate 20. The airbag cover 22 may include other features, such as a network of reinforcing ribs along one or both of the illustrated outer surface and the opposing inner surface. The airbag cover 22 is attached to the adjacent panel portion 24 at a hinge area 32 along the perimeter 26. In this example, the hinge area 32 is along one of the long sides of the rectangular perimeter 26. These may be molded-in features or features that are added after the panel 10 is molded or otherwise formed.

[0034] The hinge region 32 is configured to remain intact during airbag deployment and maintain attachment of the cover 22 to the adjacent panel portion 24. This may be accomplished in part by the hinge region 32 being continuous along its length, by minimizing the number of through openings along the hinge region 32, and / or by providing the hinge region 32 with a flexible shape that tends to bend rather than break.

[0035] refer to Figures 2 to 4 The airbag net 34 is provided to help maintain the attachment of the airbag cover 22 to the adjacent panel portion 24 during deployment of the airbag 30, even if the molded plastic portion at the hinge area 32 is broken. Thus, the airbag net 34 is a reinforcement layer of the hinge area 32 and extends at least across the hinge area (in the Y direction). The airbag net 34 can be glued or otherwise attached to the substrate 20, or can be at least partially embedded in the material of the substrate 20. It is also possible to omit the plastic material at the hinge area 32 so that the airbag net 34 itself is the hinge.

[0036] The airbag mesh 34 is located on the outer side 36 of the substrate 20 to structurally reinforce the hinge area 32. The airbag mesh 34 has an inner side 38 and an outer side 40, wherein the inner side 38 is attached to the outer side 36 of the substrate 20 at the location of the airbag cover 22. The airbag mesh 34 can be completely positioned within the perimeter 26 of the airbag cover 22, or in some embodiments, can at least partially extend beyond the perimeter 26. Advantageously, the airbag mesh 34 extends completely along the hinge area 32 in the Y direction, as shown in FIG. Figure 3 This arrangement helps ensure that the airbag cover 22 does not separate from the airbag net 34 , such as during deployment of the airbag 30 .

[0037] As a reinforcement layer, the airbag net 34 can be made of a stronger material and / or in a stronger form (such as a fiber sheet) than the plastic material used for the substrate 20. In one example, the airbag net 34 includes aramid fibers or is made entirely of aramid fibers. The aramid fibers or aramid fiber blends can be in the form of a woven fabric sheet, a melt-bonded web, or an integrally extruded web. The airbag net 34 can include any uniformly arranged flexible sheet of twisted material with openings at least as wide as the strands between the strands. For example, aramid fiber strands with a diameter of 0.5 mm, woven together with 0.5 mm or more spaces between the strands, can constitute the airbag net 34. To give a few examples, the airbag net 34 can also be a woven or non-woven fabric layer including natural fibers, synthetic fibers, glass fibers, or carbon fibers. The airbag net 34 can be formed of a metal material, such as a wire mesh or metal fabric, a metal foil, or a thin sheet of metal. In one embodiment, the airbag net 34 is a reinforcement layer made of polyester (eg, PET, PBT, 1100DTEX, 2200DTEX). Advantageously, in some embodiments, the airbag net 34 has an elongation of about 15% and not less than 5%.

[0038] refer to Figure 2 and Figure 3, the airbag net 34 has a hinge 42 having a first net segment 44 located on a first side of the hinge and a second net segment 46 located on an opposite second side of the hinge. In the illustrated embodiment, the hinge 42 of the airbag net 34 extends in the Y direction and is aligned with the hinge area 32 of the airbag cover 22. The first net segment 44 is coupled to the adjacent panel portion 24, and the second net segment 46 is coupled to the airbag cover 22. The first and second net segments 44, 46 can be indirectly coupled to the panel 10, such as via one or more adhesive layers, etc., or can be directly coupled to the panel, such as molded in or otherwise integrated. In one embodiment, the inner side 38 of the airbag net 34 is attached to the substrate 20 so that the hinge 42 is a folded portion that angles the first net segment 44 relative to the second net segment 46.

[0039] like Figure 3 , the airbag net 34 includes a first side 48 and an opposing second side 50, as well as a third side 52 and an opposing fourth side 54. The airbag net 34 in this embodiment has a rectangular shape, wherein the length of the first and second sides 48, 50 is shorter than the length of the third and fourth sides 52, 54. In addition, the hinge 42 extends completely between the first and second sides 48, 50, and in some embodiments, may extend beyond the hinge area 32 of the airbag cover 22. The hinge 42 may extend completely between the first and second sides 48, 50, while also including other features, such as various cut-throughs or material bridges, to help selectively control the opening and attachment of portions of the panel 10.

[0040] In the illustrated embodiment, the first and second sides 48, 50 are configured to be at least partially aligned with the X direction of the vehicle 14, and the third and fourth sides 52, 54 are configured to be at least partially aligned with the Y direction of the vehicle. In this arrangement, the hinge 42 of the airbag net 34 and the hinge area 32 of the airbag cover 22 are generally parallel to the longest extent of the windshield 56 in the Y direction. In addition, the longest extent of the airbag net 34 is aligned with the hinge 42 extending in the Y direction.

[0041] The airbag mesh 34 includes a strategically positioned reinforcing fold 58. In existing embodiments, a double layer structure is used to reinforce the airbag mesh 34, as opposed to the primarily single layer structure shown in the illustrated embodiment. Alternatively, the reinforcing fold 58 is positioned in line with the hinge 42 (i.e., in the Y direction). However, in this embodiment, the reinforcing fold 58 is configured to extend from the first mesh segment 44 through the hinge 42 to the second mesh segment 46, rather than extending along the hinge. Thus, the reinforcing fold 58 is configured to extend partially in the X direction, and in this embodiment, completely in the X direction, extending completely between the third side 52 and the fourth side 54. This arrangement is particularly advantageous because the reinforcing fold 58 is better positioned to increase the strength of the airbag mesh 34 in the tensile direction and to better respond to the tensile forces generated by the airbag 30 during opening of the airbag cover 22. As Figure 3 As shown, the airbag cover 22 is configured to rotate relative to the slideway about the Y axis, as indicated by arrow 59, such that the Y axis is the axis of rotation. The reinforcing fold 58 is configured perpendicular to the cover rotation axis or the Y axis.

[0042] like Figure 4 , the reinforcing fold 58 is constructed with at least three overlapping layers 60, 62, 64. In this embodiment, the reinforcing fold 58 has an S-shaped cross-section 66. This arrangement extending transversely across the hinge 42 helps to increase the strength of the airbag net 34 by three times, and positioning the reinforcing fold 58 in a tensile direction related to the force of opening the airbag cover 22 can help to increase the local strength. In addition, when used with more modern airbags 30, lateral modifications to the net 34 used to control the opening of the cover can improve the panel 10. In previous embodiments, the airbags were much smaller (e.g., 60L) and opened slower (e.g., 12msec), compared to the airbag 30 which is proportionally larger (e.g., 140L) and opens much faster (e.g., 2msec). Positioning the reinforcing fold 58 in a direction transverse to the hinge 42 helps to accommodate these increases in size and reductions in the deployment time of the airbag 30. If the panel 10 is modified to have, for example, an H-shape, rather than the U-shape illustrated for the airbag cover 22 , the reinforcing fold 58 and hinge 42 may be configured differently than shown in the illustrated example. However, the reinforcing fold 58 will still be oriented generally perpendicular to the hinge 42 .

[0043] Figure 4The reinforcing fold 58 is shown to be located in the center portion CS between the first side 48 and the second side 50. The center portion CS includes a center point 68 between the first side 48 and the second side 50, which is located in the middle of the second overlapping layer 62. The length of the center portion CS between the first side 48 and the second side 50 is less than 50% of the total distance between the first side and the second side. Even more advantageously, the length RFL of the reinforcing fold 58 between the first side 48 and the second side 50 is completely located within the center portion CS. The location of the three overlapping layers 60, 62, 64 within the center portion CS helps to triple the strength of the initial impact area 70 where the airbag 30 deploys. This length RFL of the reinforcing fold 58 can be customized according to the functional requirements of the panel 10. In addition, although the reinforcing fold 58 is strategically positioned in the airbag net 34, other folds, bends, etc. can be positioned in the net according to the desired specific implementation.

[0044] The forces generated on the hinge 42 of the airbag net 34 generally grow from the cover center region at the initial impact area 70 and the center portion CS in the cross-vehicle direction (Y direction) to the cover side edge regions located along the first and second side edges 48 , 50 . Figure 4 The vertically projected arrows in Schematic represent the force development curve of the airbag 30 and also illustrate the dynamic airbag interaction between the module and the cover 22 . Figure 5 1 shows how the panel 10 deforms rapidly when the airbag 30 contacts the outer side 40 of the airbag net 34 and expands through the airbag cover 22. Positioning the reinforcing fold 58 transverse to the cross-vehicle direction in the center portion CS can help improve the connection between the airbag cover 22 and the adjacent panel portion 24 by tripling the strength along the initial impact area 70. In addition, the first end 72 of the reinforcing fold 58 and the second end 74 of the reinforcing fold 58 are strategically positioned within the center portion CS and also extend beyond the initial impact area 70. Like the reinforcing fold 58 itself, the first end 72 and the second end 74 both extend in a direction transverse to the hinge 42 (in the illustrated embodiment, in the X direction, and more specifically, perpendicular to the hinge 42). After the cushion of the airbag 30 contacts the airbag cover 22 of the panel 10, tensile forces begin to grow exponentially at the mesh hinge 42 and hinge area 32, and the location of the reinforced fold 58 can help prevent the strength of the airbag mesh from being undesirably overcome compared to folds extending at other locations or along / aligned with the hinge.

[0045] The reinforcing fold 58 may be formed in the airbag net 34 before or during attachment to the substrate 20. For example, the net 34 may be pre-folded before being placed on a conveyor or into a molding tool, and the molding tool may be used to apply heat and pressure to help retain the reinforcing fold 58. In other embodiments, the reinforcing fold 58 may be sewn, attached by an adhesive layer, pressed, or welded into the airbag net 34, to name a few. In a preferred implementation, the folding of the reinforcing fold 58 provides at least three overlapping layers 60, 62, 64 in the center portion CS, and leaves a first and second web segment 76, 78 on either side of the ends 72, 74 of the fold 58, each of which is a single layer.

[0046] Figure 6 and Figure 7 Another embodiment of the reinforcing fold 58' is shown. In this embodiment, the same reference numerals are used to represent the same features, and the teachings of the reinforcing fold 58 with respect to the previous figures are also applicable to the reinforcing fold 58'. The reinforcing fold 58' has an Ω-shaped cross section 80, forming two longitudinal sections 82, 84, each of which is oriented transversely with respect to the hinge 42, or more specifically oriented vertically. The first longitudinal section 82 has three overlapping layers 60, 62, 64 and a first end 72 and a second end 74. The second longitudinal section 84 also includes three overlapping layers 86, 88, 90, which form a third end 92 and a fourth end 94. In this embodiment, the overlapping layers 64, 90 form a continuous top 96 of the Ω-shaped cross section 80. This arrangement also provides better planar alignment of the first and second segments 76, 78 relative to the single layer. The gap 98 can be located near the center point 68 to at least partially define the first and second longitudinal sections 82, 84. In some embodiments, the longitudinal portions 82, 84 may abut or be close at the center point 68. Typically, the length of each longitudinal segment RFS1, RFS2 between the first and second side edges 48, 50 of the airbag net 34 is equal to half the total length of the reinforcement fold 58' (RFL).

[0047] It should be understood that the above is a description of one or more embodiments of the present invention. The present invention is not limited to the specific embodiments disclosed herein, but is limited only by the following appended claims. In addition, the statements contained in the foregoing description relate to specific embodiments and should not be interpreted as limitations on the scope of the present invention or the definitions of the terms used in the claims, unless the terms or phrases are clearly defined above. For those skilled in the art, various other embodiments and various changes and modifications to the embodiments disclosed by the present invention will become apparent. All such other embodiments, changes and modifications are intended to fall within the scope of the appended claims.

[0048] As used in this specification and claims, the terms "example," "for example," "for example," "such as," and "similar," and the verbs "include," "have," "comprise," and their other verb forms, when used in conjunction with a list of one or more components or other items, should each be interpreted as open-ended, meaning that the list should not be considered to exclude other additional components or items. Other terms should be interpreted using their broadest reasonable meaning unless they are used in a context that requires a different interpretation. In addition, the term "and / or" will be interpreted as an inclusive OR. Thus, for example, the phrase "A, B, and / or C" will be interpreted to cover all of the following: "A"; "B"; "C"; "A and B"; "A and C"; "B and C"; and "A, B, and C."

Claims

1. A vehicle interior panel, characterized in that: The vehicle interior panel comprises: an airbag cover configured to cover a deployable airbag; an adjacent panel portion, the adjacent panel portion being positioned adjacent the airbag cover; and An airbag net having a hinge formed between a first net segment located on a first side of the hinge and a second net segment located on an opposite second side of the hinge, wherein the first net segment is coupled to the adjacent panel portion and the second net segment is coupled to the airbag cover, wherein the airbag net includes a reinforcing fold extending through the hinge from the first net segment to the second net segment.

2. The vehicle interior trim panel according to claim 1, characterized in that: The reinforcement fold has at least three overlapping layers.

3. The vehicle interior trim panel according to claim 2, characterized in that: The reinforcing folded portion has an S-shaped cross section.

4. The vehicle interior trim panel according to claim 2, characterized in that: The reinforcement fold has two sections, each section having at least three overlapping layers.

5. The vehicle interior trim panel according to claim 4, characterized in that: The reinforcing fold has an Ω-shaped cross section.

6. The vehicle interior trim panel according to claim 1, characterized in that: Each of the first network segment and the second network segment is a single-layer airbag net.

7. The vehicle interior trim panel according to claim 1, characterized in that: The airbag net has a first side, a second side, a third side and a fourth side, wherein the third side is one end of the first net segment and the fourth side is one end of the second net segment.

8. The vehicle interior trim panel according to claim 7, characterized in that: The hinge extends completely from the first side to the second side.

9. The vehicle interior trim panel according to claim 7, characterized in that: The reinforcement fold extends completely from the third side edge to the fourth side edge.

10. The vehicle interior trim panel according to claim 7, characterized in that: The vehicle interior panel includes a central portion located between the first side and the second side, wherein the central portion includes a center point located between the first side and the second side, and a length of the central portion between the first side and the second side is less than 50% of a total distance between the first side and the second side.

11. The vehicle interior trim panel according to claim 10, characterized in that: The reinforcing fold is positioned entirely within the central portion.

12. The vehicle interior trim panel according to claim 7, characterized in that: The first side and the second side are configured to extend at least partially along an X-direction relative to the vehicle.

13. The vehicle interior trim panel according to claim 12, characterized in that: The longest extent of the reinforcement fold is configured to extend at least partially in the X-direction relative to the vehicle.

14. The vehicle interior trim panel according to claim 1, characterized in that: The hinge is a folded portion that angles the first web segment relative to the second web segment.

15. The vehicle interior trim panel according to claim 1, characterized in that: The reinforcing fold is located along an initial impact region where the deployable airbag is configured to make initial contact with the airbag cover.

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