Crash pad module

Abstract

A crash pad module includes: a crash pad; an airbag door configured to open in a first direction when a portion of the crash pad is cut; and a substrate inserted in the crash pad and the airbag door, the substrate including a bent portion formed by bending a portion of the substrate, a through hole being formed in a hinge portion of the airbag door, and the bent portion being disposed at a position corresponding to the through hole.

Description

[0001] Cross - reference to related applications

[0002] This application claims the priority and benefit of Korean Patent Application No. 10 - 2024 - 0003570, filed on January 9, 2024, the entire disclosure of which is incorporated herein by reference for all purposes. Technical Field

[0003] The present invention relates to a bumper pad module, a mold for manufacturing the bumper pad module, and a method of manufacturing the bumper pad module using the mold, and more particularly, to a bumper pad module whose substrate can easily hold and support an airbag door when the airbag is deployed, a mold for manufacturing the bumper pad module, and a method of manufacturing the bumper pad module using the mold. Background Art

[0004] Airbags (specifically, passenger airbags (PABs)) are used to minimize harm to passengers when a vehicle collision occurs. Such airbags are installed in a bumper pad, and when an airbag door provided at a side portion of the bumper pad is opened, the pad is deployed to protect the passengers.

[0005] When the PAB is deployed, the airbag door opens toward the passengers, and the airbag is deployed. In this case, since there is a possibility that the airbag door may be damaged due to the expansion force of the airbag, a substrate is provided to prevent damage to the airbag door and to prevent separation toward the passengers. The substrate has a net - like structure in the form of a substrate sheet, is inserted by injection, and is used to hold the airbag door member when the airbag is deployed.

[0006] Conventional substrates are designed to peel off and separate from the wall of the airbag fitting to compensate for the insufficient length of the airbag door. Therefore, the length of the substrate peeling off and separating can be increased by the high pressure of the inflator, and in some cases, the substrate can be completely separated from it. Particularly, in the case of electric vehicles, since the interior space of the vehicle is further expanded, and the airbag for covering the expanded space is further enlarged, a high - pressure inflator may be used. When a conventional substrate is used in an electric vehicle, a phenomenon in which the substrate is completely peeled off or separated may occur.

[0007] When the substrate is completely peeled off and separated from it, the airbag door may be damaged, and the airbag door may cause harm to the passengers due to separation toward the passengers. Therefore, there is a need for a bumper pad module that can prevent the airbag door member from peeling off and separating and can stably hold the airbag door member, and a device for manufacturing the bumper pad module. Summary of the Invention

[0008] The present invention content is provided to introduce some concepts that will be further described in the following detailed description in a simplified form. The present invention content is not intended to identify the key features or essential features of the claimed subject matter, nor is it intended to be used to assist in determining the scope of the claimed subject matter.

[0009] In a general aspect, a bumper pad module is provided herein, which includes: a bumper pad; an airbag door configured to open in a first direction when a part of the bumper pad is cut; and a substrate inserted into the bumper pad and the airbag door. The substrate includes a bent portion formed by bending a part of the substrate. A through hole is formed in the hinge portion of the airbag door, and the bent portion is disposed at a position corresponding to the through hole.

[0010] The through hole may be defined as a long hollow shape extending in the longitudinal direction of the hinge portion, and a bridging member connecting the portions of the through hole in the width direction is formed inside the through hole.

[0011] The through hole may be provided as one of a plurality of through holes, and the plurality of through holes are spaced apart from each other at a predetermined distance in the longitudinal direction of the hinge portion.

[0012] The bumper pad module may include: an airbag fitting configured to protrude from the rear surface of the bumper pad along the edge portion of the airbag door.

[0013] The bumper pad module may include: a reinforcing rib provided on a portion of the rear surface of the airbag door in contact with the airbag fitting.

[0014] The bumper pad, the airbag door, and the airbag fitting may be integrally formed.

[0015] The thickness of the bridging member is the same as the thickness of the airbag door.

[0016] An empty portion corresponding to the bridging member may be provided in the bent portion of the substrate.

[0017] The bumper pad module may include: an injection material configured as a film on the inner surface of the bent portion.

[0018] The bent portion may be configured to stretch and translate when the airbag door is deployed to compensate for the deployment stress on the substrate and the airbag door.

[0019] In general, the present invention provides a crash pad module, the crash pad module comprising: a crash pad; an airbag door configured to open in a first direction when a part of the crash pad is cut, the airbag door including a hinge portion having a through hole defined therein; and a substrate inserted into the crash pad and the airbag door, the substrate including a bent portion formed by bending a part of the substrate, the bent portion being provided at a first position on the substrate corresponding to a second position of the through hole in the airbag door.

[0020] The crash pad module may include: a bridge member configured to connect portions of the through hole in a width direction, the bridge member being formed inside the through hole, the through hole being defined as a long hollow shape extending in a longitudinal direction of the hinge portion.

[0021] The bent portion may include an empty portion defined therein corresponding to the bridge member.

[0022] The crash pad may include an airbag fitting configured to project from a rear surface of the crash pad along an edge portion of the airbag door.

[0023] The crash pad may include a reinforcing rib provided at a third position where a rear surface of the airbag door contacts the airbag fitting.

[0024] The reinforcing rib may be configured to absorb stress between a rear surface of the airbag door and a side surface of the airbag fitting.

[0025] The bent portion may be configured to stretch and translate when the airbag door is deployed to fix the airbag door and compensate for deployment stress on the substrate and the airbag door. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a view showing a crash pad module according to an embodiment of the present invention;

[0027] Figure 2 is a view showing an airbag door of a crash pad module according to an embodiment of the present invention;

[0028] Figure 3 is a view showing an airbag door according to another embodiment of the present invention;

[0029] Figure 4 is a cross-sectional view showing a portion where a through hole of an airbag door is formed according to an embodiment of the present invention;

[0030] Figure 5 is a cross-sectional view showing a portion where a through hole of an airbag door is formed according to another embodiment of the present invention;

[0031] Figure 6is a cross-sectional view showing a portion of a bridge member in which an airbag door is formed according to an embodiment of the present invention;

[0032] Figure 7 is a view showing a substrate according to an embodiment of the present invention;

[0033] Figure 8 is a rear view showing a bumper pad module according to an embodiment of the present invention;

[0034] Figure 9 is a cross-sectional view showing a portion of a through hole in which an airbag door is formed according to another embodiment of the present invention;

[0035] Figure 10 is a cross-sectional view showing an airbag door according to another embodiment of the present invention;

[0036] Figure 11 is a view showing an opened airbag door of a bumper pad module according to an embodiment of the present invention;

[0037] Figure 12 is a view showing a lower mold of a mold for manufacturing a bumper pad module according to an embodiment of the present invention;

[0038] Figure 13 is a view showing a lower mold and a pressing jig of a mold for manufacturing a bumper pad module according to an embodiment of the present invention;

[0039] Figure 14 is a view showing a pressing jig of a mold for manufacturing a bumper pad module that bends a substrate according to an embodiment of the present invention;

[0040] Figure 15 is a view showing a bent substrate disposed on a lower mold of a mold for manufacturing a bumper pad module according to an embodiment of the present invention;

[0041] Figure 16 is a view showing a lower mold and an upper mold of a mold for manufacturing a bumper pad module being engaged with each other according to an embodiment of the present invention; and

[0042] Figure 17 is a flowchart showing a method of manufacturing a bumper pad module using a mold for manufacturing a bumper pad module according to an embodiment of the present invention.

[0043] Throughout the drawings and the detailed description, unless otherwise described or provided, identical or similar reference numerals can be understood to refer to identical or similar elements, features, and structures. The drawings may not be to scale, and for clarity, illustration, and convenience, the relative dimensions, proportions, and descriptions of elements in the drawings may be enlarged. Detailed Description

[0044] The following detailed description is provided to assist the reader in obtaining a comprehensive understanding of the methods, apparatuses, and / or systems described herein. However, various changes, variations, and equivalents of the methods, apparatuses, and / or systems described herein will be apparent after understanding the disclosure of this application. For example, as will be apparent after understanding the disclosure of this application, except for operations that must occur in a specific order, the order of operations described herein is merely exemplary and is not limited to those set forth herein, but may be changed.

[0045] The features described herein may be embodied in different forms and should not be construed as limited to the embodiments described herein. Instead, the embodiments described herein are provided merely to illustrate some of the many possible ways of implementing the methods, apparatuses, and / or systems described herein that will be apparent after understanding the disclosure of this application.

[0046] Advantages and features of the present disclosure, as well as methods of achieving the advantages and features, will become apparent with reference to the embodiments described in the following detailed description and the drawings. However, the present disclosure is not limited to the embodiments disclosed herein, but may be implemented in various forms. The embodiments of the present disclosure are provided so that the present disclosure is fully disclosed and those of ordinary skill in the art can fully understand the scope of the present disclosure. The present disclosure will be limited only by the scope of the appended claims. At the same time, the terms used in this specification are used to explain the embodiments and not to limit the present disclosure.

[0047] Terms such as first, second, A, B, (a), (b), etc. may be used herein to describe components. Each of these terms is not used to define the nature, order, or sequence of the corresponding component, but is merely used to distinguish the corresponding component from other components. For example, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component.

[0048] Throughout the specification, when a component is described as "connected to" or "coupled to" another component, it may be directly "connected to" or "coupled to" another component, or there may be one or more other components therebetween. In contrast, when an element is described as "directly connected to" or "directly coupled to" another element, there may be no other elements therebetween.

[0049] In the description of the embodiments, in a case where any one element is described as being formed above or below another element, such description includes a case where the two elements are formed in direct contact with each other and a case where the two elements are in indirect contact with each other by means of one or more other elements interposed between the two elements. Further, when an element is described as being formed above or below another element, such description may include a case where an element is formed on the upper side or the lower side with respect to another element.

[0050] Unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" are intended to include the plural forms as well. It should also be understood that when used herein, the terms "comprises" and / or "comprising" indicate the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0051] Hereinafter, embodiments of a vehicle controller heat dissipation module will be described in detail with reference to the accompanying drawings. When describing the embodiments with reference to the accompanying drawings, the same or corresponding components will be denoted by the same reference numerals, and redundant descriptions thereof will be omitted.

[0052] Hereinafter, a surface formed in the direction in which the airbag door 20 is deployed or in the direction from the bumper pad 10 to the windshield is defined as the front surface, and a surface formed to face the inner space of the bumper pad 10 is defined as the rear surface.

[0053] The bumper pad 10 covers components at the front side of the vehicle, and in the event of an accident, an airbag installed inside the bumper pad 10 is deployed to protect passengers. The bumper pad 10 is manufactured by a method of injecting a plastic resin into a mold. The airbag door 20 may be formed on a portion of the bumper pad 10 where the airbag is installed. The airbag door 20 can be opened by the inflation pressure of the airbag, and the airbag pad can be deployed toward the passengers.

[0054] The airbag door 20 is opened in such a manner that at least a part of the airbag door 20 is cut in one surface of the bumper pad 10. In order to prevent the airbag door 20 from being damaged and separating toward the passengers or the windshield and in order to stably support the airbag door, a scrim 40 is provided inside the airbag door 20 and the bumper pad 10.

[0055] When manufacturing the bumper pad 10, the scrim 40 formed of a scrim material may be inserted into the mold in advance, and then an injection material may be injected so that the scrim 40 can be inserted into the bumper pad 10. The scrim 40 actually serves as a hinge portion of the airbag door 20 and becomes a rotation axis of the airbag door 20 when the airbag door 20 is opened.

[0056] However, since the substrate 40 is formed of a substrate material, when a high voltage is applied to the substrate 40, there is a problem that the substrate 40 is torn or elongated and cannot properly support the airbag door 20. In particular, when the substrate 40 does not have an extra length, there is a problem that when the airbag door 20 is opened, the hinge portion of the substrate 40 is elongated or damaged, and the airbag door 20 is separated due to the high inflation pressure of the airbag.

[0057] Therefore, an impact pad module is needed in which an extra length of the substrate 40 is fixed and which stably supports the airbag door 20. The present invention relates to an impact pad module in which a hole is formed in the hinge portion of the airbag door 20, and a bent portion 42 is formed at a portion of the substrate 40 corresponding to the hole, so that the substrate 40 has an extra length. The present invention provides an impact pad module, a mold for manufacturing the impact pad module, and a method of manufacturing the impact pad module using the mold, in which when the airbag is deployed and the airbag door 20 is opened, the bent portion 42 compensates for the insufficient length to stably support the airbag door 20.

[0058] Figure 1 is a view showing an impact pad module according to an embodiment of the present invention.

[0059] See Figure 1 , an impact pad module according to an embodiment of the present invention may include: an impact pad 10; an airbag door 20 that opens when at least a part of the impact pad 10 is cut; and a substrate 40 inserted into the impact pad 10 and the airbag door 20.

[0060] In the case of the present invention, the impact pad module may be applied to an integrated model in which the impact pad 10, the airbag door 20, and the substrate 40 are integrally formed. The substrate 40 may be pre-inserted into the mold before the impact pad 10 and the airbag door 20 are injection molded, and then the injection material may be injected so that the substrate 40 may be inserted into the impact pad 10 and the airbag door 20.

[0061] A passenger airbag (PAB) for protecting a passenger may be provided on the rear surface of the impact pad 10. An airbag suit 30 connected to the airbag module may be formed on the rear surface of the impact pad 10.

[0062] The airbag suit 30 may be formed to protrude from the rear surface of the impact pad 10 along a portion where the airbag module is provided. The airbag door 20, at least a part of which is cut and opened in one direction, may be formed in the impact pad 10.

[0063] The direction in which the airbag door 20 opens is towards the interior of the vehicle, and the airbag door 20 can open towards the windshield in front of the passenger. The airbag door 20 can be formed to cover the part where the airbag fitting 30 and the airbag module are provided, and the cutting line 21 can be formed along the edge of the airbag door 20.

[0064] When the airbag is deployed, the cutting line 21 at the edge of the airbag door 20 can be cut by the pressure of the airbag, and then the airbag door 20 can be opened. The airbag door 20 can be opened based on the side where it is connected to the bumper pad 10 as a hinge part. Therefore, when the airbag door 20 is opened, the part corresponding to the hinge part can not be cut and can support the airbag door 20.

[0065] Generally, the materials used to form the airbag door 20 and the bumper pad 10 are plastic resins, and when the airbag door 20 is opened, the material deforms while being stretched on one side of the hinge part or the airbag door 20 is peeled off due to the high inflation pressure of the airbag. When the hinge part of the airbag door 20 is excessively deformed, the opening degree of the airbag door 20 may increase, or the deployment of the airbag pad may be disturbed.

[0066] When the airbag door 20 is opened excessively, the airbag door 20 can separate towards the passenger or collide with the windshield and affect the safety of the passenger. Therefore, a substrate 40 is inserted into the airbag door 20 and the bumper pad 10, and the substrate 40 is a mesh net formed of a substrate material and serves as the actual hinge part of the airbag door 20. The substrate 40 can be formed of a flexible material and deform flexibly to provide additional length to the side of the hinge part and hold the airbag door 20 even when a high pressure is applied thereto.

[0067] However, as described above, when the airbag door 20 is opened excessively, the substrate 40 is damaged (e.g., torn) and can not properly support the airbag door 20. When the airbag door 20 is opened, a force is applied to the part corresponding to the hinge part in the direction in which it is deployed and stretched, and the substrate 40 is stretched or peeled off from the airbag door 20 and the bumper pad 10, and can not properly support the airbag door 20.

[0068] According to an embodiment of the present invention, a bent part 42 is formed in the substrate 40 so that the part corresponding to the hinge part has additional length. At least a part of the substrate 40 can be bent at the bent part 42 and has as much additional length as the bent part.

[0069] After the substrate 40 is disposed in the mold, since the injection material is injected to form the bumper pad 10 and the airbag door 20, the shape of the mold can be preset to prevent the injection material from filling the portion corresponding to the bent portion 42 of the substrate 40. When the bent portion 42 of the substrate 40 is formed along the shape of the mold, since the corresponding portion is not filled with the injection material, a through hole 22 can be formed in the hinge portion of the airbag door 20.

[0070] Figure 2 The view of the airbag door of the bumper pad module according to an embodiment of the present invention is shown.

[0071] Refer to Figure 2 , in the airbag door 20 of the bumper pad module according to an embodiment of the present invention, a cutting line can be formed along the edge and the portion to be opened, and a through hole 22 can be formed in the portion corresponding to the hinge portion of the airbag door 20.

[0072] The through hole 22 can be formed in a long hollow shape along the hinge portion of the airbag door 20. The through holes 22 can be provided as a plurality of through holes 22 formed at a predetermined distance from each other, and a bridge member 23 filling the empty space can be formed between the plurality of through holes 22.

[0073] The bridge member 23 can prevent deformation of the bumper pad 10 and the airbag door 20, fill at least a part of the through hole 22, and prevent peeling of the substrate 40 when the airbag door 20 and the bumper pad 10 are injection-molded. Since a plurality of through holes 22 can be formed, a plurality of bridge members 23 can be formed in a predetermined manner.

[0074] The width of the bridge member 23 can be formed to be the same as the width of the through hole 22, and the thickness of the bridge member 23 can be formed to be the same as the thickness of the airbag door 20. Since a decorative material such as a leather cover is formed on the front surface of each of the bumper pad 10 and the airbag door 20, when the through hole 22 is formed to have a large width, the decorative material can fall into the through hole 22 and deform the outside.

[0075] In order to prevent the mark of the through hole 22 from being exposed to the outside, the width of the through hole 22 can be formed to be small. For example, when the width of the through hole 22 is 2 mm or less, the shape of the through hole 22 can be prevented from being exposed to the outside.

[0076] Since the thickness of the bridge member 23 is formed to be the same as the thickness of the airbag door 20, the front surface of the bridge member 23 can be formed to be coplanar with the front surface of the airbag door 20, and thus the mark of the through hole 22 can be prevented from being exposed to the outside. That is, the bridge member 23 can support the decorative material and prevent the decorative material from falling into the through hole 22.

[0077] The bent portion 42 of the substrate 40 may be located at the portion where the through hole 22 is formed. The bent portion 42 may be formed at the rear side of the through hole 22, and the substrate 40 may not be exposed from the front surface of each of the airbag door 20 and the bumper pad 10.

[0078] Figure 3 A diagram of an airbag door according to other embodiments of the present invention is shown.

[0079] See Figure 3 , in the hinge portion of the airbag door 20 according to another embodiment of the present invention, a through hole 22 may be formed, and a bridging member 23 may not be formed inside the through hole 22. During the injection molding process of the bumper pad 10 and the airbag door 20, the through hole 22 may be formed while the protruding portion of the mold blocks the injection material from being injected into the corresponding space.

[0080] When the portion protruding from the mold is integrally formed to extend in the longitudinal direction of the hinge portion of the airbag door 20, only one through hole 22 having a long hollow shape may be formed in the hinge portion of the airbag door 20.

[0081] When one through hole 22 is formed, since it is difficult to prevent the external decorative material from falling into the through hole 22 through the through hole 22, the width of the through hole 22 may be smaller than the width of the through hole in the case where the bridging member 23 is formed therein.

[0082] In Figures 1 to 3 , although a large width of the through hole 22 is shown for ease of understanding, the actual width of the through hole 22 may be smaller than the shown width and the external decorative material may be prevented from falling.

[0083] Figure 4 A cross-sectional view of a portion where a through hole of an airbag door is formed according to an embodiment of the present invention is shown, Figure 5 A cross-sectional view of a portion where a through hole of an airbag door is formed according to still another embodiment of the present invention is shown.

[0084] Figure 4 And Figure 5 Are cross-sectional views taken along line A-A in Figure 2 . See Figure 4 , a substrate 40 is shown disposed within the airbag door 20 and the airbag fitting 30. There is a substrate 40 for the overall bumper pad 10, where the substrate is molded into a straight shape or is molded to be bent into Shape. In the case of the present embodiment, it is shown that the bumper pad module is applied with a substrate 40 molded to be bent in the shape of . In the case of the present embodiment, the bent portion of the substrate 40 may be disposed inside the airbag fitting 30.

[0085] The bent portion 42 formed in the substrate 40 may be formed to bend at the rear side of the through hole 22 formed in the hinge portion of the airbag door 20. When the airbag door 20 is opened, the bent portion 42 may be stretched and may hold the airbag door 20.

[0086] See Figure 5 , which shows a cross-section of the bumper pad module to which the substrate 40 formed in a straight shape is applied. When manufacturing the bumper pad module, the injection material is injected in a state where the straight substrate 40 is not molded into a stretched state before being pre-arranged in the mold. Therefore, as Figure 5 shown, both ends of the straight substrate 40 are provided inside the bumper pad 10 and not inside the airbag fitting 30.

[0087] Figure 6 Shows a cross-sectional view of a part of the bridge member in which the airbag door is formed according to an embodiment of the present invention.

[0088] Figure 6 Shows a cross-sectional view along Figure 2 the line B-B in Figure 6 . See

[0089]

[0090] Figure 7

[0091] Figure 7

[0092] ​​​​​The bent portion 42 is bent to protrude toward the rear surface of the airbag door 20, and the bent portion 42 corresponds to the position of the through hole 22 formed in the hinge portion of the airbag door 20. The bent portion 42 may be formed to extend in the longitudinal direction of the hinge portion, and the portion where the bridging member 23 is formed in the bent portion 42 may be formed to be cut and hollow.

[0093] In the bent portion 42 of the substrate 40, since the portion corresponding to the bridging member 23 is formed to be cut, a support member for maintaining the shape of the bent portion 42 can be formed during the manufacturing process of the bumper pad module. The support member may be formed in a shape in which the bent portion 42 of the substrate 40 extends and is provided on the rear surface of the bridging member 23. That is, when the injection material is injected, the support member may be formed in such a way that at least some of the injection material is injected into the cut portion in the bent portion 42 of the substrate 40. Since the substrate 40 is formed of a substrate material and has a flexible characteristic, the support member can support the substrate 40 to maintain the shape of the bent portion 42 during the manufacturing of the bumper pad module.

[0094] Figure 8 A rear view of a bumper pad module according to an embodiment of the present invention is shown.

[0095] See Figure 8 According to an embodiment of the present invention, a bumper pad module may include a bumper pad 10, an airbag door 20, and an airbag fitting 30 protruding from the rear surface of the airbag door 20 along the edge of the airbag door 20.

[0096] The substrate 40 is inserted into the airbag door 20 and the airbag fitting 30. The substrate 40 may be arranged to cover a part of the airbag door 20. For example, the width of the substrate 40 may be formed to cover 50% or more of the airbag door 20. In the case of the present embodiment, a substrate 40 smaller than the width of the airbag door 20 is shown. The bent portion 42 of the substrate 40 is provided in the hinge portion of the airbag door 20. The bent portion 42 may be provided as a plurality of bent portions 42, and the plurality of bent portions 42 are formed to be spaced apart from each other by a predetermined distance in the longitudinal direction.

[0097] Figure 9 A cross-sectional view of a portion in which a through hole of an airbag door is formed according to another embodiment of the present invention is shown.

[0098] Refer to Figure 9 The injection material may be injected on the inner side of the bent portion 42 of the substrate 40 so that the bent portion 42 can be molded in the form of a thin film. The protruding pin 310 of the upper mold 300 may be inserted into the bent portion 42 of the substrate 40, and then the injection material may be injected, and thus the injection material can be prevented from being injected into the bent portion 42.

[0099] The width of the protruding pin 310 can be formed to correspond to the inner space of the bent portion 42 of the substrate 40. Alternatively, the width of the protruding pin 310 can be formed to be smaller than the inner space of the bent portion 42 of the substrate 40. When the protruding pin 310 is separated from the inner surface of the bent portion 42 of the substrate 40 by a predetermined distance, an injection material can be injected into the corresponding space to cover a thin layer on the inner surface of the bent portion 42.

[0100] The injection material covering the inner surface of the bent portion 42 can be used to hold the airbag door 20 by utilizing the bent portion 42 when opening the airbag door 20. In addition, when the strength of the hinge obtained only from the substrate 40 is insufficient, the insufficient strength can be compensated. In an embodiment, during airbag deployment, when the hinge portion cannot translate in the deployment direction and generates stress (e.g., deployment stress) on the airbag door 20, causing the airbag, the airbag door 20, and the substrate 40 to peel off and / or be damaged, the bent portion 42 can absorb the stress by allowing compensatory translation of the substrate 40.

[0101] Figure 10 A cross-sectional view of an airbag door according to another embodiment of the present invention is shown;

[0102] See Figure 10 , according to still another embodiment of the present invention, the bumper pad module may further include a reinforcing rib 32 connecting the airbag fitting 30 and the airbag door 20.

[0103] The portion of the airbag door 20 directly disposed on the side surface of the hinge portion may be subjected to a strong force due to the expansion force when the airbag door 20 is deployed, and thus there is a possibility that the substrate 40 peels off from the bumper pad 10 and the airbag fitting 30. Although the bent portion 42 of the substrate 40 can compensate for the insufficient length of the hinge portion to prevent the peeling of the substrate 40, the reinforcing rib 32 can be formed to more stably prevent the peeling of the substrate 40. In addition, when the reinforcing rib 32 is formed, breakage that may occur in the airbag door 20 and the airbag fitting 30 can be prevented.

[0104] The reinforcing rib 32 can be formed to connect the rear surface of the airbag door 20 and the side surface of the airbag fitting 30. The reinforcing rib 32 can be provided as a plurality of reinforcing ribs 32, and the plurality of reinforcing ribs are formed to be spaced apart from each other by a predetermined distance in the longitudinal direction in which the through hole 22 is formed in the hinge portion of the airbag door 20. The reinforcing rib 32 can be formed in a triangular shape to connect the rear surface of the airbag door 20 and the side surface of the airbag fitting 30.

[0105] There is no limitation on the shape and number of the reinforcing ribs 32, and any shape and any number of reinforcing ribs 32 can be applied as long as the stress applied to the rear surface of the airbag door 20 and the side surface of the airbag fitting 30 can be dispersed by the reinforcing ribs 32 and the possible cracking and peeling of the substrate 40 can be prevented when the airbag door 20 is opened.

[0106] Figure 11 is a view showing an opened airbag door of a bumper pad module according to an embodiment of the present invention.

[0107] See Figure 11 , when the PAB is deployed, the airbag door 20 can rotate forward and open. When the airbag door 20 is opened, the airbag door 20 rotates around the hinge portion. In this case, the hinge portion is elongated and supports the airbag door 20.

[0108] The bent portion 42 of the substrate 40 can be stretched according to the rotation of the airbag door 20 to compensate for the insufficient length of the hinge portion. Therefore, tearing or peeling of the airbag door 20 and the substrate 40 due to elongation can be prevented.

[0109] The windshield is arranged in the direction in which the airbag door 20 is opened. When the airbag door 20 is opened and the distance that the airbag door 20 moves from the bumper pad module increases, the airbag door 20 may collide with the windshield, and thus it may be difficult to protect the passengers.

[0110] The length of the bent portion 42 of the substrate 40 that supports the airbag door 20 can be set such that the airbag door 20 does not collide with the windshield. For example, the length of the bent portion 42 can be formed to be less than 6 mm to prevent the airbag door 20 from colliding with the windshield.

[0111] Hereinafter, a mold for manufacturing a bumper pad module according to an embodiment of the present invention will be described with reference to the drawings.

[0112] A mold for manufacturing a bumper pad module according to an embodiment of the present invention may include: a lower mold 100 in which a substrate base portion 110 is formed and on which the substrate 40 is disposed; an upper mold 300 engaged with the lower mold 100; and a pressing jig 200 that bends at least a part of the substrate 40 disposed in the lower mold 100.

[0113] Figure 12 is a view showing a lower mold of a mold for manufacturing a bumper pad module according to an embodiment of the present invention.

[0114] See Figure 12, a substrate base portion 110 can be formed in the lower mold 100, and the substrate 40 is disposed on the substrate base portion. Before the injection material is injected, the substrate 40 can be pre-disposed in the lower mold 100 and inserted into the bumper pad 10, the airbag door 20, and the airbag fitting 30.

[0115] As Figure 12 shown, guide pins 114 can be formed on the substrate base portion 110 to suspend the substrate 40, thereby preventing the substrate 40 from moving in the lower mold 100 when the substrate 40 is disposed on the substrate base portion 110.

[0116] The guide pins 114 can be formed to protrude from the substrate base portion 110, and at least a part of the substrate 40 can be suspended on the guide pins 114. Holes can be formed in the substrate 40 corresponding to the positions and shapes of the guide pins 114, and the substrate 40 can be fixed in such a way that the guide pins 114 are inserted into the holes. The guide pins 114 can be provided as a plurality of guide pins 114 formed on the substrate base portion 110, and the plurality of guide pins 114 can be arranged to be spaced apart from each other by a predetermined distance.

[0117] A bending groove 112 for forming the bending portion 42 of the substrate 40 can be formed in the substrate base portion 110. The bending groove 112 can be formed to be recessed inward from the substrate base portion 110 in the substrate base portion 110. The bending portion 42 of the substrate 40 can be formed by inserting at least a part of the substrate 40 into the bending groove 112. The shape of the bending groove 112 corresponds to the shape of the bending portion 42 of the substrate 40, and since the bending portion 42 can be provided as a plurality of bending portions 42, the bending groove 112 can also be provided as a plurality of bending grooves 112 corresponding to the bending portion 42.

[0118] When forming the bending portion 42 of the substrate 40, the substrate 40 is formed to be pushed into the bending groove 112, and the inner side of the bending groove 112 can be formed to have a curvature. When the inner side of the bending groove 112 is formed as a curved surface having a curvature, damage to the substrate 40 generated when the substrate 40 is inserted into the bending portion 42 can be prevented.

[0119] The bending groove 112 can not be provided in the portion of the bridge member 23 in which the airbag door 20 is formed. In the portion in which the bridge member 23 is formed, since the protruding pin 310 of the upper mold 300 is not provided, the bending groove 112 can not be provided to prevent the injection material from being introduced.

[0120] A space can be formed in the lower mold 100, and the space can be formed to correspond to the shape of the rear surface of the bumper pad 10 and the shape of the rear surface of the airbag door 20, and the airbag fitting 30 is formed in the space. Structures such as a plurality of ribs for enhancing strength can be formed on the rear surfaces of the airbag door 20 and the bumper pad 10, and the corresponding structures are formed by filling the lower mold 100 having a recessed shape with an injection material.

[0121] The airbag fitting 30 protruding from the rear surface of the airbag door 20 along the edge portion of the airbag door 20 is formed by filling an injection material into a groove formed in the lower mold 100 corresponding to the shape of the airbag fitting 30. Figure 12 Region A indicates the groove in which the airbag fitting 30 is formed.

[0122] Figure 13 Views of the lower mold and the pressing jig of the mold for manufacturing a bumper pad module according to an embodiment of the present invention are shown, and Figure 14 is a view showing a pressing jig of a mold for manufacturing a bumper pad module that bends a substrate according to an embodiment of the present invention.

[0123] Referring to Figure 13 and Figure 14 , the pressing jig 200 is configured to form a bent portion 42 of the substrate 40 after the substrate 40 is disposed on the substrate base portion 110 of the lower mold 100 and before the lower mold 100 is joined to the upper mold 300. The pressing jig 200 may include a pusher 220 and a fixing portion 210. The pusher pushes at least a part of the substrate 40 into the bending groove 112 to form the bent portion 42, and the fixing portion fixes the substrate 40 while the bent portion 42 is being formed.

[0124] The pusher 220 and the fixing portion 210 may be sequentially moved by different driving portions. Accordingly, the fixing portion 210 may move toward the lower mold 100 and fix the substrate 40 before the pusher 220 moves, and then, the pusher 220 may move toward the lower mold 100 to form the bent portion 42.

[0125] As Figure 13As shown, when the substrate 40 is disposed on the substrate base portion 110, the fixing portion 210 of the pressing jig 200 fixes both ends of the substrate 40 so that the substrate 40 does not move. The fixing portion 210 presses the front surface of the substrate 40, and vacuum suction cups 212 may be formed on both ends of the fixing portion 210 to fix the substrate 40 so that the substrate 40 does not move. The method of fixing the substrate 40 by the fixing portion 210 is not limited, and any member that can fix the substrate 40 by a different method may be applied without the vacuum suction cups 212. As an example, the substrate 40 may be fixed by the following method: a material having a high frictional force is disposed on both ends of the fixing portion 210, and both ends of the substrate 40 are pressed to provide frictional force.

[0126] As Figure 14 shown, when the fixing portion 210 fixes the substrate 40, the pusher 220 moves forward to insert at least a part of the substrate 40 into the bending groove 112. A bending protrusion 222 may be formed on the pusher 220 to push the substrate 40 into the bending groove 112. The bending protrusion 222 may be formed to correspond to the shape of the bending groove 112 of the substrate base portion 110. When the bending protrusion 222 inserts at least a part of the substrate 40 into the bending groove 112, since the substrate 40 is pulled and receives a force, the end of the bending protrusion 222 may be formed to have a curvature to prevent damage to the substrate 40 formed of the substrate material.

[0127] The portion of the fixing portion 210 corresponding to the bending groove 112 may be opened so that the bending protrusion 222 of the pusher 220 is inserted into the bending groove 112. That is, at least a part of the fixing portion 210 may be opened so that the bending groove 112 and the substrate 40 disposed in the bending groove 112 are exposed in the direction in which the pusher 220 is disposed.

[0128] The bending protrusion 222 of the pusher 220 may be formed to correspond to the shape and number of the bending grooves 112. Therefore, when the bending grooves 112 are provided as a plurality of bending grooves 112, the bending protrusions 222 may be provided as a plurality of bending protrusions 222 formed to be spaced apart from each other by a predetermined distance.

[0129] Figure 15 is a view showing a bent substrate located on a lower mold of a mold for manufacturing a bumper pad module according to an embodiment of the present invention.

[0130] Referring Figure 15 , it can be shown that the bent portion 42 of the substrate 40 is formed by the pressing jig 200. The substrate 40 may be disposed on the lower mold 100 in a state where the bent portion 42 is formed. When the bent portion 42 is formed, the substrate 40 is completely molded, and then the upper mold 300 may be provided.

[0131] The upper mold 300 is formed to correspond to the shape of the lower mold 100 and is disposed on the front surface of the lower mold 100. The upper mold 300 may be formed to correspond to the shape of the front surface of each of the bumper pad 10 and the airbag door 20, and an injection material may be injected into the space between the upper mold 300 and the lower mold 100 to form a bumper pad module.

[0132] In Figure 15 , a state before the upper mold 300 and the lower mold 100 are joined is shown. The pressing jig 200 for molding the substrate 40 moves outward from the lower mold 100, and the upper mold 300 may move toward the lower mold 100 and be joined to the lower mold 100.

[0133] Figure 16 is a view showing a lower mold and an upper mold joined to each other of a mold for manufacturing a bumper pad module according to an embodiment of the present invention.

[0134] Refer to Figure 16 , it can be shown that the upper mold 300 is disposed on the front surface of the lower mold 100 and joined to the front surface of the lower mold. Protrusion pins 310 are formed on the upper mold 300 to correspond to the curved grooves 112 of the lower mold 100.

[0135] The protrusion pins 310 may be inserted into the curved grooves 112 of the lower mold 100 and the curved portions 42 of the substrate 40 to prevent the injection material from being injected into the curved grooves 112 and the curved portions 42. The width of the protrusion pins 310 may be a length obtained by subtracting the thickness of the curved portion 42 of the substrate 40 from the width of the curved grooves 112. That is, the protrusion pins 310 may be formed to correspond to the inner thickness of the curved portion 42 of the substrate 40.

[0136] The protrusion pins 310 may be inserted into the curved portions 42 of the substrate 40, and thus the injection material may not be injected into the curved portions 42. Alternatively, the protrusion pins 310 may be formed inside the curved portions 42 of the substrate 40 at a predetermined distance from the side surfaces of the curved portions 42. That is, the diameter of the curved protrusions 222 may be larger than the diameter of the protrusion pins 310. When the protrusion pins 310 are disposed in the curved portions 42 at a predetermined distance from the side surfaces of the curved portions 42, the injection material may be injected using the corresponding distance and the injection material in the form of a film may be applied on the inner side of the curved portions 42.

[0137] The length of the protrusion pins 310 may be a length obtained by adding the thickness of the portion corresponding to the airbag door 20 and the depth of the curved portions 42. In Figure 16In this case, region B corresponds to a portion formed by the airbag door 20 and the bumper pad 10. Accordingly, the protruding pin 310 may protrude from a surface of the upper mold 300 by a length obtained by adding the height of region B to the depth of the bent portion 42.

[0138] Hereinafter, a method of manufacturing a bumper pad module using a mold for manufacturing a bumper pad module having the above-described configuration will be described in detail.

[0139] Figure 17 FIG. shows a flowchart of a method of manufacturing a bumper pad module using a mold for manufacturing a bumper pad module according to an embodiment of the present invention.

[0140] Referring to Figure 17 , a method of manufacturing a bumper pad module according to an embodiment of the present invention includes: disposing a substrate 40 in a lower mold 100 (operation S10); bending the substrate 40 (operation S20); engaging an upper mold 300 with the lower mold 100 (operation S30); and injecting an injection material (operation S40).

[0141] In Figure 17 the method of manufacturing a bumper pad module shown in Figures 12 to 16 the mold for manufacturing a bumper pad module shown in can be sequentially set and processed.

[0142] Before injecting the injection material, the substrate 40 may be disposed in the lower mold 100. The substrate 40 may be disposed in the lower mold 100 in such a manner as to be disposed on a substrate base 110 formed in the lower mold 100. The substrate 40 may be suspended on a guide pin 114 formed on the substrate base 110 so that the position of the substrate 40 can be fixed.

[0143] After disposing the substrate 40, operation S20 of bending the substrate 40 may be performed. Operation S20 of bending the substrate 40 may include disposing a pressing jig 200 on the front surface of the lower mold 100, moving the pressing jig 200 to insert a bending protrusion 222 into a bending groove 112, and inserting the substrate 40 into the bending groove 112 and bending the substrate 40.

[0144] Since the bending groove 112 is formed to be recessed into the substrate base 110 of the lower mold 100, the bending protrusion 222 formed on the pusher 220 of the pressing jig 200 may push the substrate 40 into the bending groove 112 to bend at least a portion of the substrate 40. The portion bent by the bending protrusion 222 may form a bent portion 42 of the substrate 40.

[0145] When the substrate 40 is bent, the outer side of the substrate 40 can be fixed by the lower mold 100 and the fixing part 210 of the pressing jig 200. The fixing part 210 can fix the substrate 40 by pressing the outer side of the substrate 40 against the lower mold 100 to provide frictional force. Alternatively, a vacuum chuck 212 can be formed on the fixing part 210 and can suck the outer side of the substrate 40 to fix the substrate 40.

[0146] After bending the substrate 40, an operation S30 of engaging the upper mold 300 with the lower mold 100 can be performed. The operation S30 of engaging the upper mold 300 with the lower mold 100 can include separating the pressing jig 200 from the lower mold 100, arranging the upper mold 300 on the front surface of the lower mold 100, and moving the upper mold 300 to insert the protruding pin 310 into the bending groove 112.

[0147] The upper mold 300 and the lower mold 100 are provided with predetermined spaces A and B therebetween, and an injection material is injected into the corresponding spaces to form a bumper pad module. The protruding pin 310 can be formed on the upper mold 300 and inserted into the bent portion 42 of the substrate 40.

[0148] When the protruding pin 310 is inserted into the bent portion 42 of the substrate 40, the protruding pin 310 can prevent the injection material from being injected into the bent portion 42 and the bending groove 112. The injection material can fill the spaces A and B between the upper mold 300 and the lower mold 100 to form a bumper pad 10, an airbag door 20, and an airbag fitting 30.

[0149] In the method of manufacturing a bumper pad module, the substrate 40 can be arranged in the lower mold 100 by an automatic multi-joint robot. Specifically, the substrate 40 can be arranged on the substrate base 110 of the lower mold 100 by an insertion chuck formed at the end of the automatic multi-joint robot. The insertion chuck can provide the substrate 40 and includes a pressing jig 200 to mold the bent portion 42.

[0150] According to an embodiment of the present invention, when the bent portion of the substrate inserted into the bumper pad and the airbag door extends and the airbag door is deployed, the insufficient length can be compensated, and the airbag door can be stably supported.

[0151] The various embodiments of the present disclosure do not list all available combinations, but are used to describe the representative aspects of the present disclosure. The descriptions of the various embodiments can be independently applied or can be applied by a combination of two or more.

[0152] Multiple embodiments have been described above. However, it should be understood that various modifications can be made. For example, suitable results can be achieved if the described techniques are performed in a different order and / or if the components in the described system, architecture, device, or circuit are combined in a different manner and / or the components in the described system, architecture, device, or circuit are replaced or supplemented by other components or their equivalents. Accordingly, other embodiments are within the scope of the appended claims.

[0153] Although this disclosure includes specific embodiments, it will be apparent after understanding the disclosure of this application that various changes in form and detail can be made in these embodiments without departing from the spirit and scope of the claims and their equivalents. The embodiments described herein are considered in a descriptive sense only and not for purposes of limitation. The description of a feature or aspect in each embodiment is considered applicable to a similar feature or aspect in other embodiments. Suitable results can be achieved if the described techniques are performed in a different order and / or if the components in the described system, architecture, device, or circuit are combined in a different manner and / or the components in the described system, architecture, device, or circuit are replaced or supplemented by other components or their equivalents. Accordingly, the scope of this disclosure is not limited by the detailed description but by the claims and their equivalents, and all variations within the scope of the claims and their equivalents should be construed as being included in this disclosure.

Claims

1. A bumper pad module, comprising: A bumper pad; An airbag door configured to open in a first direction when a part of the bumper pad is cut; And A substrate inserted into the bumper pad and the airbag door, Wherein the substrate includes a bent portion formed by bending a part of the substrate, Wherein a through hole is formed in the hinge portion of the airbag door, and Wherein the bent portion is disposed at a position corresponding to the through hole.

2. The anti-collision pad module according to claim 1, wherein The through hole is defined as a long hollow shape extending in the longitudinal direction of the hinge portion; and Wherein a bridging member connecting the portions of the through hole in the width direction is formed inside the through hole.

3. The anti-collision pad module according to claim 2, wherein, The through hole is provided as one of a plurality of through holes, and the plurality of through holes are spaced apart from each other at a predetermined distance in the longitudinal direction of the hinge portion.

4. The bumper pad module according to claim 2, further comprising: An airbag fitting configured to protrude from the rear surface of the bumper pad along the edge portion of the airbag door.

5. The bumper pad module according to claim 4, further comprising: A reinforcing rib provided on a portion of the rear surface of the airbag door in contact with the airbag fitting.

6. The anti-collision pad module according to claim 4, wherein, The bumper pad, the airbag door, and the airbag fitting are integrally formed.

7. The anti-collision pad module according to claim 2, wherein, The thickness of the bridging member is the same as the thickness of the airbag door.

8. The anti-collision pad module according to claim 2, wherein, An empty portion corresponding to the bridging member is provided in the bent portion of the substrate.

9. The bumper pad module according to claim 1, further comprising: An injection material configured as a film on the inner surface of the bent portion.

10. The anti-collision pad module according to claim 1, wherein, The bent portion is configured to stretch and translate when the airbag door is deployed to compensate for the deployment stress on the substrate and the airbag door.

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