Method for producing a cover of an airbag module

Abstract

The invention relates to a method for producing a cover (1) for an airbag module. The covers (1) each have a receiving region (2) for at least one decorative element visible to an occupant in the assembled state of the cover (1). The covers (1) are each produced between a first mold half (5) on the nozzle side and a second mold half (6) on the ejection side of an injection mold (4). By means of at least one replacement insert (5A or 6A) or a plurality of replacement inserts (5A or 6A) embedded in each of the first mold half (5) and / or the second mold half (6), the first mold half (5) and / or the second mold half (6) can be replaced. 6A) for adapting the receiving region (2) of the first batch of covers (1) and the receiving region (2) of the at least one second batch of covers (1) by embedding at least one further replacement insert or a plurality of further replacement inserts to a decorative element (10) which is implemented differently and is to be embedded in the receiving region (1).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a cover for an airbag module according to the type further defined in the preamble of claim 1. Background Technology

[0002] A cover for an airbag module is known from EP2687413A1. The cover includes decorative elements, or decorative components, having a front side and a back side. When the cover is connected to the airbag module, the front side of the cover is visible. Furthermore, a mounting element is provided, disposed on the back side of the decorative element and configured for mounting the cover to the housing of the airbag module. The mounting element is formed by injection molding the decorative element and is directly connected to it thereon.

[0003] Such covers are typically manufactured using plastic injection molding, resulting in high mold costs when there are multiple different covers and decorative elements. Summary of the Invention

[0004] The objective of this invention is to provide a method by which a cover for an airbag module for use in decorative elements implemented in different locations can be manufactured in a simple and cost-effective manner.

[0005] According to the present invention, this task is solved using a method having the features of claim 1.

[0006] Using the method according to the invention, a cover for an airbag module is manufactured between a first mold half on the nozzle side and a second mold half on the ejection side of an injection mold. Each cover has a receiving area for at least one decorative element visible to the passenger in the assembled state of the cover.

[0007] According to the invention, the receiving area of ​​the first batch of cover is adapted to decorative elements that are implemented differently and to be embedded in the receiving area by means of at least one replacement insert respectively embedded in the first mold half or the second mold half, and by means of other replacement inserts replacing the replacement inserts.

[0008] Alternatively, it is feasible to adapt the receiving area of ​​the first batch of cover to decorative elements that are implemented differently and to be embedded in the receiving area by means of multiple replacement inserts respectively embedded in the first mold half and the second mold half, and by means of multiple other replacement inserts replacing the replacement inserts.

[0009] By utilizing various alternatives to the method according to the invention, different decorative elements or logos important for brand communication can be integrated into largely identical cover parts in a simple and cost-effective manner using different replaceable inserts in the airbag cover mold. This achieves maximum possible differentiation of the cover parts with the best possible initial investment, i.e., with both development and mold costs kept low.

[0010] In other words, different brand logos can be integrated into the cover of the airbag module in a cost-effective manner using the method according to the invention, the cover being different from each other only in its receiving area.

[0011] The receiving areas of the cover can be arranged within the fracture line, which is manufactured in the cover through the mold half and / or by replacing the insert. Along the fracture line, the cover breaks open and releases an opening for the airbag when the airbag module is triggered. Because different configurations of the receiving areas do not affect the design of the fracture line of the cover, the costly development required for each airbag module to operate flawlessly is avoided.

[0012] Each of the cover elements in the receiving area may have at least one opening. To securely connect the decorative element to the cover element, a connector of the decorative element may be insertable into these openings. Such a connector may protrude beyond the back side of the decorative element, which faces the front side of the receiving area of ​​the cover element in the assembled state. In this case, the decorative element can be mounted on the cover element with minimal cost and preferably in the desired orientation.

[0013] The front side of the receiving area of ​​the cover can be configured with a topology or a curved surface, with the front side facing the back side of the decorative element to be embedded in the receiving area of ​​the cover. Such a topology or curved surface allows for support of the decorative element on the back side and prevents deformation of the element and the resulting operating noise, such as that caused by the so-called Knackfroscheffekt effect. This is particularly advantageous when the decorative element is made of a thin sheet of metal on the front side.

[0014] In another advantageous variation of the method according to the invention, at least the first batch of coverings are each constructed with at least one connection area for a decorative element, which is at least partially illuminated. Through such connection areas, the illuminated decorative element can be connected to the vehicle's electrical onboard and control systems.

[0015] When at least the plug-in elements of the decorative elements are made of plastic and pass through the openings of the receiving area of ​​the cover, in another variation of the method according to the invention, the plug-in elements are thermally riveted or ultrasonically welded to the cover for the fixed connection between the decorative elements and the cover, respectively, on the back side of the cover.

[0016] If at least the plug elements of the decorative element are made of metal and these plug elements pass through the openings in the receiving area of ​​the cover, then in another variation of the method according to the invention that can be implemented with low cost, the free ends of the plug elements are bent or riveted to the cover on the back side of the cover for the fixed connection of the decorative element.

[0017] The front side of the cover can be covered with at least a covering layer made of artificial leather or natural leather. This allows undesirable visible mold parting lines in the area of ​​the cover to be easily concealed and remain invisible to the vehicle's passengers.

[0018] Alternatively or in place of this, the cover may be provided with a leather grain or design edge, at least in the area on its front side, in order to conceal the desired visible mold parting line.

[0019] Furthermore, it can be specified that the cover members in the receiving area each have component weights adapted to the component weights of the decorative elements to be respectively fixed thereto. This adaptation can be configured such that the sum of the component weights of each batch of cover members and the different decorative elements respectively connected thereto is at least approximately the same. This allows for the simple compensation of weight differences between the different decorative elements to be fixed through the injection-molded structure, thereby achieving uniform burst characteristics upon airbag deployment.

[0020] In principle, it is feasible to implement the receiving area as a recess in the cover. In other words, the front side of the cover is offset rearward in the receiving area relative to the rest of the front side of the cover, thereby constructing the receiving area as at least generally bowl-shaped.

[0021] The outer perimeter of the receiving area can be adapted to the outline of the decorative element to be placed therein and, for example, implemented as circular, triangular, quadrangular, polygonal, or trapezoidal, or each can be manufactured in any other suitable outline shape for receiving the decorative element. Attached Figure Description

[0022] Further advantages and advantageous improvements of the invention can be seen from the claims and the embodiments described in principle with reference to the accompanying drawings.

[0023] in:

[0024] Figure 1 A front view of a cover for an airbag module is shown, the cover having a receiving area for decorative elements visible to the passenger in the assembled state of the cover.

[0025] Figure 2 Showing according to Figure 1 Rear view of the cover;

[0026] Figure 3 A highly simplified longitudinal sectional view of an injection mold, configured for manufacturing according to... Figure 1 Covering components;

[0027] Figure 4 Showing according to Figure 1 A three-dimensional partial view of the receiving area of ​​a feasible embodiment of the cover;

[0028] Figure 5 Showing according to Figure 4 A partial longitudinal sectional view of the receiving area of ​​the cover, wherein the decorative element is embedded in the receiving area;

[0029] Figure 6 Showing according to Figure 4 The receiving area of ​​the cover corresponds to Figure 4 The view shows decorative elements embedded in the receiving area;

[0030] Figure 7 Showing according to Figure 1 Another implementation of the receiving area of ​​the cover corresponds to Figure 4 Diagram;

[0031] Figure 8 Showing according to Figure 7 The corresponding cover Figure 5 The illustration shows decorative elements embedded in the cover;

[0032] Figure 9 The corresponding injection mold is shown Figure 3 As shown in the diagram, other replacement inserts are embedded into the injection mold on the ejector side and the nozzle side;

[0033] Figure 10 A schematic rear view showing another embodiment of the cover, the cover being transmitted via... Figure 9 The replacement inserts shown in the diagram are used for manufacturing;

[0034] Figure 11 Showing the manufacturing process in Figure 12 The injection mold of the cover element is schematically shown in medium to high detail, corresponding to... Figure 9 Diagram;

[0035] Figure 12 The corresponding embodiment of the cover is shown. Figure 10 Diagram;

[0036] Figure 13 The corresponding embodiment of the cover is shown below. Figure 10 Diagram;

[0037] Figure 14 The corresponding injection mold is shown Figure 9 As shown in the diagram, other replacement inserts are embedded in the injection mold, and break lines can be locally created through these other replacement inserts.

[0038] Figure 15 Showing the corresponding cover Figure 10 The diagram shows that the covering utilizes... Figure 14 Manufacturing by replacing inserts;

[0039] Figure 16 The corresponding injection mold is shown Figure 14 The illustration shows other replacement inserts used to create cover parts. Figure 17 The embodiment further illustrated herein is embedded in the injection mold;

[0040] Figure 17 The corresponding embodiment of the cover is shown. Figure 15 The diagram shows that, in the cover, the break line has a shape in the receiving area that corresponds to the shape of the cover. Figure 15 The fracture lines of the covering parts have different directions.

[0041] Figure 18 The corresponding embodiment of the cover is shown. Figure 10 Diagram;

[0042] Figure 19 A simplified single view of the illuminated decorative element is shown;

[0043] Figure 20 Showing according to Figure 19 Rear view of the decorative element;

[0044] Figure 21 Showing according to Figure 19 A front view of a decorative element fitted onto a diffuser sheet; and

[0045] Figure 22 Showing according to Figure 19 A cross-sectional view of the decorative element. Detailed Implementation

[0046] Figure 1The diagram shows a front view of a cover 1, which is an airbag cover for an airbag module (not shown further in the drawings). Such an airbag module is particularly integrated into the steering wheel of a vehicle to protect the driver. The cover 1 forms the front side of the airbag module housing and is fitted onto and fixedly connected to the lower part of the housing. Additionally, in Figure 2 The image shows a rear view of the cover 1.

[0047] The cover 1 is respectively in Figure 1 and Figure 2 A receiving area 2 is constructed within the circle K, which is further characterized in that it is configured to receive decorative elements, such as brand logos or the like. The circular shape of the receiving area 2 is currently chosen solely for display purposes and can be arranged within another closed line, including curved lines and / or straight lines, depending on the respective usage scenarios. In the assembled state of the cover 1, the decorative element is mounted within the receiving area 2 at the front 3 of the cover 1 and is visible to the passenger.

[0048] Figure 3 A schematic longitudinal sectional view of an injection mold 4 is shown, comprising a mold half 5 on the nozzle side and a mold half 6 on the ejection side. To manufacture the cover 1 and the receiving area 2, so-called replacement inserts 5A or 6A are embedded not only in the mold half 5 on the nozzle side but also in the mold half 6 on the ejection side. Through these replacement inserts 5A and 6A, the receiving area 2 can be constructed or implemented differently with low cost and in a cost-effective manner, and can be adapted to decorative elements of different constructions without altering the remaining areas of the cover 1.

[0049] Alternatively, the receiving area 2 may be constructed or implemented differently by replacing only one of the replacement inserts 5A or 6A.

[0050] Figure 4 A possible embodiment of the receiving area 2 of the cover 1 is shown, the receiving area having an opening 7 and a defined topology 8. Here, according to Figure 4 The topology 8 of the receiving area 2 of the cover 1 includes a tab 9 extending along the circumferential direction U and also along the radial direction R of the receiving area 2, the tab being in Figure 5 and Figure 6 The decorative element 10, further shown in the diagram, is positioned in an assembled state to support the decorative element. The decorative element 10 has a plug-in element 11, which is provided when the decorative element 10 is assembled according to... Figure 4During the installation of the cover element 10, the insert element 11 is inserted into the opening 7 from the front side 3 of the cover element 1. In the assembled state of the decorative element 10, the insert element 11 passes through the opening 7 of the cover element 1 and protrudes beyond the back side 12 of the cover element 1 in the vertical direction Z. Subsequently, the free end 13 of the insert element 11 is bent to fix the decorative element 10 to the cover element 1.

[0051] Figure 7 Another embodiment of the cover 1 or receiving area 2 is shown. Figure 4 As shown in the diagram, the receiving area is configured with multiple openings 14, and the plug-in element 11 of the decorative element 10 is used to... Figure 8 The method further illustrated allows for insertion into or partially through the openings. According to... Figure 8 The decorative element 10 includes a decorative upper side 15, which is mounted on a support element 16, preferably made of plastic, and the support element is provided with a plug-in element 11.

[0052] Alternatively, the decorative element 10 may be made entirely of plastic and have a material or similar material applied to its upper decorative side 15 by means of spray painting or PVD coating. Alternatively, the upper side of the decorative element 10 may be made of metal, such as aluminum, and the like, and the upper side may be attached to a support element made of plastic.

[0053] The plug element 11 of the bracket element 16 is first inserted into the opening 14 with its free end 13 and is clipped, heat-riveted, welded, or otherwise fixedly connected to the cover 1 on the back side 12 of the cover 1. Figure 8 In the figures, the plug-in elements and their free ends are further characterized by reference numerals 11 and 13 before hot riveting, respectively; conversely, the plug-in elements and their free ends after hot riveting are represented by reference numerals 11A and 13A, respectively.

[0054] Additionally, it is possible, according to Figure 8 The decorative element 10 is fixedly connected to the cover 1 by bending the free end 13 of the plug element 11 or by thermal riveting the free end 13 of the plug element 11. Alternatively, the plug element 11 can be fixedly connected to the cover 1 by means of ultrasonic welding.

[0055] Figure 9 The injection mold 4 is shown corresponding to Figure 3The diagram shows that additional replacement inserts 59A or 69A are embedded in the mold halves 5 and 6, respectively. With the aid of these replacement inserts 59A and 69A, the cover 1 or its receiving area 2 is configured with low cost to adapt to the structure of the decorative element 10 to be connected thereto, the decorative element being exemplary in its shape, height, and weight. Figure 5 or Figure 8 The decorative element 10 shown in the image is different.

[0056] As is well known, the cover 1 of the airbag module is respectively implemented with, for example, in Figure 2 Further shown is the fracture line 17, or so-called split line or crack edge, along which the cover 1 releases an opening when the airbag module is triggered, through which the explosively deployed airbag bag protrudes and cushions the passenger's impact.

[0057] With the help of Figure 9 The injection mold 4 shown in the figure manufactures the fracture line 17 in the cover member 1 via the mold half 6 on the nozzle side. It is feasible here that the fracture line 17 has respectively... Figure 10 The direction shown in the image. Figure 10 The break line 17 of the cover 1 surrounds the receiving area 2 with an arc-shaped segment 17A extending above the receiving area 2, and bracket-shaped sub-segments 17B and 17C of the break line 17 are respectively connected to the segment on the outside.

[0058] Figure 11 The injection mold 4 is shown corresponding to Figure 9 The diagram shows that other replaceable inserts 511A and 611A are embedded in the injection mold so that it can be manufactured in Figure 12 The receiving area 2 is schematically shown in the diagram, and the receiving area is implemented in a substantially quadrangular shape. The break line 17 is further formed in the back side 12 of the cover 1 during the manufacture of the cover 1 by means of the mold half 6 on the nozzle side.

[0059] Figure 13 This illustrates another possible implementation of the receiving area 2 with the cover 1. Figure 12 As shown in the diagram, the cover can be manufactured at a low mold cost by means of other replacement inserts 513A, 613A that can be embedded in the mold halves 5 and 6, and is also compatible with other decorative elements 10.

[0060] Alternatively, it is feasible to connect a one-piece decorative element or a decorative element composed of multiple parts to the cover 1 separately. It can be specified here that the decorative element implemented in a multi-piece manner achieves its final appearance only through form-locking with the cover 1.

[0061] Additionally, Figure 14 The injection mold 4 is shown corresponding to Figure 9 As shown in the diagram, additional replacement inserts 514A and 614A are embedded in the injection mold on the nozzle side and ejection side. Through these additional replacement inserts 514A and 614A, the receiving area 2 is manufactured to have... Figure 15 The outer circular shape is schematically shown in the diagram, and the break line 17 also has... Figure 15 The cover 1 is shown in the diagram. Here, bracket-shaped segments 17B and 17C of the break line 17 are manufactured in the cover 1 via the mold half 6 on the ejector side. In contrast, the arcuate runout 17A of the break line 17 is manufactured within the receiving area 2 via a replacement insert 614A on the ejector side. This reduces the visibility of the break line 17, which improves the overall optical impression of the vehicle.

[0062] Figure 16 The injection mold 4 shown has other replacement inserts 516A and 616A corresponding to Figure 14 The diagram illustrates that, through the aforementioned other replacement inserts, it is possible to manufacture [something] with [something]. Figure 17 The shielding member 1 of the receiving area 2 is schematically shown in the diagram. According to... Figure 15 The arc-shaped orientation of the cover 1 17A is based on Figure 17 The cover 1 has a substantially triangular orientation that adapts to the rectangular periphery of the receiving area 2. According to... Figure 17 The triangular direction 17A of the fracture line 17 of the cover part 1 is generated in the cover part 1 during the plastic injection molding process via the replacement insert 616A on the ejector side. In contrast, according to... Figure 17 The bracket-shaped sections 17B and 17C of the fracture line 17 of the cover part 1 are formed by the mold half 6 on the ejection side.

[0063] Figure 18 The diagram shows another embodiment of the cover 1 corresponding to... Figure 15 The diagram shows that the break line 17 includes an upper segment 17D and a lower segment 17E. The upper segment 17D and the lower segment 17E each have at least a generally U-shaped orientation. An arcuate orientation 17A of the break line 17 extends between the two U-shaped segments 17D and 17E, connecting the two U-shaped segments 17D and 17E and laterally enclosing the circular receiving area 2.

[0064] Figure 19 A single view showing another embodiment of the decorative element 10 that is capable of illumination or lighting. For this purpose, the decorative element 10 includes LEDs 18, which are arranged on the back side 19 of the decorative element 10 and... Figure 20The optical conductor 20, further shown in the diagram, is in connection. The optical conductor 20 is configured on its peripheral side according to… Figure 19 The decorative element 10 is surrounded by and fixedly connected to the support 21. A decorative element 22 is mounted on the front side of the support 21, the decorative element being... Figure 21 The diffuser 23, further shown in the diagram, surrounds and is mounted on the front side of the support 21. The diffuser 23 is constructed of a PC film.

[0065] As shown in the figure Figures 19 to 21 Longitudinal sectional view of decorative element 10 Figure 22 As can be seen, the bracket 21 includes a hole 24 for receiving a plug-in element of the decorative element 22 and a so-called welding pin 25, through which the decorative element 10 can be fixedly connected to the cover 1.

[0066] List of reference numerals

[0067] 1 Covering component

[0068] 2 receiving area

[0069] 3. Front side of the cover

[0070] 4 Injection molds

[0071] 5. Mold half on the nozzle side of the injection mold

[0072] 5A Replacement Insert

[0073] 6. Mold half on the ejector side of the injection mold

[0074] 6A Insert Replacement

[0075] 7. Opening of the cover

[0076] 8. Topology of the receiving area

[0077] 9 receiving area splicing

[0078] 10 decorative elements

[0079] 11. Connecting elements for decorative components

[0080] 11A heat-riveted plug-in element

[0081] 12 back side of the cover

[0082] 13 Free ends of plug-in components

[0083] The free end of the 13A heat-riveted connector

[0084] 14. Openings in the receiving area

[0085] 15. Decorative upper side

[0086] 16 bracket components

[0087] 17 fracture lines

[0088] The arc-shaped orientation of the 17A fracture line

[0089] The bracket-shaped section of the 17B fracture line

[0090] bracket-shaped section of the 17C fracture line

[0091] 18 LED

[0092] 19 Decorative elements on the back

[0093] 20 photoconductors

[0094] 21 supports

[0095] 22 Decorative Components

[0096] 23 Scattering Plates

[0097] 24 holes

[0098] 25 welding pins

[0099] 59A Insert Replacement

[0100] 69A Insert Replacement

[0101] 511A Insert Replacement

[0102] 514A Insert Replacement

[0103] 516A Insert Replacement

[0104] 611A Insert Replacement

[0105] 614A Insert Replacement

[0106] 616A Insert Replacement

[0107] K Circle

[0108] R radial direction

[0109] U-shaped direction

[0110] Z vertical direction

Claims

1. A method for manufacturing a cover (1) for an airbag module, wherein, The cover (1) has a receiving area (2) for at least one decorative element (10; 22) visible to passengers in the assembled state of the cover, and is manufactured between a first mold half (5) on the nozzle side and a second mold half (6) on the ejection side of the injection mold (4), characterized in that the receiving area of ​​the first batch of cover (1) is made visible to passengers by at least one replacement insert (5A or 6A) or multiple replacement inserts (5A, 6A) respectively embedded in the first mold half (5) and / or the second mold half (6), and is characterized in that the receiving area of ​​the first batch of cover (1) is made visible by at least one replacement insert (5A or 6A) or multiple replacement inserts (5A, 6A) respectively embedded in the first mold half (5) and / or the second mold half (6), and is made visible by at least one replacement insert (5A or 6A) or multiple replacement inserts (5A, 6A) embedded in the first mold half (5) and / or the second mold half (6), and is made visible by at least one replacement insert (5A, 6A) respectively. (2) And by replacing the replacement insert (5A, 6A) with at least one other replacement insert (59A, 69A; 511A, 611A; 514A, 614A; 516A, 616A) or with multiple other replacement inserts (59A, 69A; 511A, 611A; 514A, 614A; 516A, 616A) respectively, the receiving area (2) of at least one second batch of cover (1) is adapted to the decorative elements (10; 22) respectively implemented differently and to be embedded in the receiving area (2).

2. The method according to claim 1, characterized in that, The receiving areas (2) of the cover (1) are respectively arranged within the fracture line (17), the fracture line is made in the cover (1) through the mold halves (5, 6) and / or through the replacement inserts (516A, 616A), and along the fracture line, the cover (1) breaks open and releases an opening for the airbag bag when the airbag module is triggered.

3. The method according to claim 1 or 2, characterized in that, The cover (1) is provided with at least one opening (7) in the receiving area (2). In order to fix the decorative element (10) to the cover (1), the plug-in element (11) of the decorative element (10) can be inserted into the opening. The plug-in element protrudes beyond the back side (19) of the decorative element (10), which faces the front side (3) of the receiving area (2) of the cover (1) in the assembled state of the decorative element (10).

4. The method according to A, characterized in that, The front side (3) of the receiving area (2) of the cover (1) is constructed with a topology (8) or a curved surface, which supports the decorative element (10) on the back side and prevents the element (10) from deforming.

5. The method according to any one of the preceding claims, characterized in that, At least the first batch of cover pieces (1) are each constructed with at least one connection area for a decorative element (22), the decorative element being at least partially illuminated, and the illuminated decorative element (22) being able to be connected to the vehicle's electrical onboard and control system through the connection area.

6. The method according to any one of the preceding claims, characterized in that, At least the plug-in element (11) of the decorative element (10) is made of plastic. The plug-in element passes through the opening (7) of the receiving area (2) of the cover (1) and is heat-riveted or welded to the cover (1) on the back side (12) of the cover (1) for the fixed connection between the decorative element (10) and the cover (1).

7. The method according to any one of the preceding claims, characterized in that, At least the plug element (11) of the decorative element (10) is made of metal and passes through the opening (7) of the receiving area (2) of the cover. The free end (13) of the plug element (11) is bent or riveted to the cover (1) on the back side (12) of the cover (1) for the fixed connection between the decorative element (10) and the cover (1).

8. The method according to any one of the preceding claims, characterized in that, The front side of the cover is covered with at least one layer made of artificial leather or natural leather (3).

9. The method according to any one of the preceding claims, characterized in that, The cover (1) is provided with a leather grain or design edge at least in the area of ​​its front side (3).

10. The method according to any one of the preceding claims, characterized in that, The cover (1) is provided with component weights in the receiving area (2) such that the component weights are adapted to the component weights of the decorative elements (10) to be fixed thereon, such that the sum of the component weights of each batch of cover (1) and the different decorative elements (10) to which they are respectively connected is at least approximately the same.

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