VEHICLE DASHBOARD AND FOLDABLE AIRBAG DEPLOYMENT FLAP

Abstract

An airbag deployment door for a motor vehicle, the airbag deployment door comprising a panel and a hinge formed along one side of the panel. The hinge is configured to be coupled to a panel on the vehicle to allow the panel to pivot, a tear seam extends on an opposite side of the panel, the tear seam configured to open during deployment of an airbag, and a score line extends in a generally Y-shape through the panel to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag.

Description

AREA OF REVELATION

[0001] The present disclosure relates generally to motor vehicles equipped with airbags, and more particularly to a passenger airbag door generally integrated into the instrument panel of a motor vehicle. GENERAL STATE OF THE ART

[0002] Motor vehicles are commonly equipped with deployable passenger airbags. Airbags can deploy from a trim panel, such as the instrument panel. Typically, the airbag includes an airbag door that opens during airbag deployment and pivots around the trim panel along an edge during deployment. Different dashboard design programs or configurations require different airbag door configurations. It is contemplated to provide an airbag door configured to deploy efficiently near a windshield. SUMMARY OF REVELATION

[0003] According to a first aspect of the present disclosure, an airbag deployment door for a motor vehicle includes a panel, a hinge formed along one side of the panel to couple to a panel on the vehicle to allow the panel to pivot, a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag, and a score line extending through the panel in the form of a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag.

[0004] Embodiments of the first aspect of the present disclosure may include any one or a combination of the following features: - the airbag deployment flap is configured to be coupled to a dashboard in the motor vehicle; - the score line covers a reduced thickness of the plate; - the tear seam includes a reduced thickness of a dashboard; - the first hinge comprises a dashboard material with reduced thickness; - the airbag deployment flap is intended for a passenger airbag located in front of a passenger seat in the motor vehicle; and - the airbag door is located in an instrument panel relative to the vehicle behind a vehicle windshield, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag.

[0005] According to a second aspect of the present disclosure, an instrument panel for a motor vehicle includes an upper trim panel configured to be mounted to the motor vehicle, and includes an airbag deployment door, a panel and a hinge formed along one side of the panel, the hinge configured to be coupled to a panel on the vehicle to allow the panel to pivot, and a tear seam extending on an opposite side of the panel. The tear seam is configured to open during deployment of an airbag, and a score line extends through the panel in a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during airbag deployment.

[0006] Embodiments of the second aspect of the present disclosure may include any one or a combination of the following features: - the airbag deployment flap is formed integrally with the dashboard in the vehicle; - the score line covers a reduced thickness of the plate; - the tear seam includes a reduced thickness of the dashboard; - the first hinge comprises a dashboard material with reduced thickness; - the airbag deployment flap is intended for a passenger airbag located in front of a passenger seat in a motor vehicle; and - the instrument panel is located behind a vehicle windshield with respect to the vehicle, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag.

[0007] Another aspect of the present disclosure is a vehicle having a windshield, an instrument panel located behind and / or below the windshield with respect to the vehicle, and an airbag system. The airbag system includes an airbag and an airbag deployment door comprising a panel, a hinge coupling one side of the panel to the instrument panel and configured to allow the panel to pivot during deployment of the airbag, a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag, and a score line extending through the panel in a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag. - the airbag deployment flap is formed integrally with the dashboard; - the score line covers a reduced thickness of the plate; - the tear seam includes a reduced thickness of the dashboard; and - the first hinge comprises a dashboard material with reduced thickness.

[0008] These and other features, advantages, and objects of the present disclosure will be better understood and appreciated by those skilled in the art by reference to the following description, claims, and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following applies in the drawings: Fig. 1 is a forward-facing view of the cabin interior of a motor vehicle equipped with a passenger airbag system having an airbag deployment door, according to one embodiment; Fig. 2 is an enlarged view of section II of Fig. 1, showing the airbag deployment flap in a deployed open position after airbag deployment; Fig. 3 is a plan view of the instrument panel and the airbag deployment door in an undeployed position; Fig. 3A is a cross-sectional view of the airbag deployment door taken along line IIIA-IIIA of Fig. 3; Fig. 3B is a cross-sectional view of the airbag deployment door taken along line IIIB-IIIB of Fig. 3; and Fig. 4 is a cross-sectional view of the passenger airbag system along lines IV-IV of Fig. 1 and shows the airbag deployment flap in a bent open position. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0010] Reference will now be made in detail to the presently preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to designate the same or similar parts. In the drawings, the illustrated structural elements are not to scale, and certain components are enlarged relative to other components for emphasis and clarity.

[0011] As required, detailed embodiments of the present disclosure are disclosed herein; however, it should be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures do not necessarily depict a detailed embodiment; some schematic representations may be exaggerated or reduced to show a functional overview. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

[0012] For the purposes of description in this document, the terms “top”, “bottom”, “right”, “left”, “back”, “front”, “vertical”, “horizontal” and derivatives thereof refer to the concepts in their orientation in Fig. 1. However, it is to be understood that the concepts may assume various alternative orientations unless expressly stated otherwise. It is also to be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following description are merely exemplary embodiments of the inventive concepts defined in the appended claims. Thus, specific dimensions and other physical characteristics are not to be considered limiting of the embodiments disclosed herein unless the claims expressly state otherwise.

[0013] The presently illustrated embodiments primarily consist of combinations of method steps and device components related to an instrument panel of a vehicle and an airbag deployment door that deploys from the instrument panel. Accordingly, the device components and method steps have been represented in the drawings by conventional symbols where appropriate, showing only those specific details relevant to an understanding of the embodiments of the present disclosure, so as not to obscure the disclosure with details that would be readily apparent to one of ordinary skill in the art in light of the present description. Furthermore, like reference numerals represent like elements in the description and the drawings.

[0014] As used herein, the term "and / or," when used in a listing of two or more elements, means that each of the listed elements may be employed individually, or any combination of two or more of the listed elements may be employed. For example, if a composition is described as containing components A, B, and / or C, the composition may contain only A; only B; only C; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0015] Herein, reference terms such as first and second, upper and lower, and the like are used merely to distinguish one entity or act from another entity or act, without necessarily requiring or implying any actual such relationship or order between such entities or acts. The terms "comprises," "comprising," or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, procedure, article, or facility that includes a list of elements not only includes those elements, but may include other elements not expressly listed or inherent in such a process, procedure, article, or facility. An element that "comprises a...’ does not exclude, without further limitation, the presence of additional identical elements in the process, procedure, article or facility incorporating that element.

[0016] As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and properties are not and need not be exact, but may be approximate and / or greater or lesser if desired, and may reflect tolerances, conversion factors, rounding off, measurement errors, and the like, and other factors known to those skilled in the art. When the term "about" is used to describe a value or range endpoint, the disclosure should be understood to include the specific value or endpoint referenced. Regardless of whether a numerical value or range endpoint includes "about" in the description, the numerical value or range endpoint is intended to include two embodiments: one modified by "about" and one unmodified by "about."It is further understood that the endpoints of each of the domains are significant both relative to the other endpoint and independently of the other endpoint.

[0017] The terms "substantially," "substantially," and variations thereof, as used herein, are intended to indicate that a described characteristic is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to mean that a surface is flat or approximately flat. Furthermore, "substantially" is intended to mean that two values ​​are equal to or approximately equal. In some embodiments, "substantially" may refer to values ​​within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0018] As used herein, the terms "the," "the," "a," or "a" or "an" mean "at least one" and are not intended to be limited to "only one" unless expressly stated otherwise. Thus, for example, a reference to "a component" includes embodiments having two or more such components, unless the context clearly indicates otherwise.

[0019] With reference to Fig. 1, a motor vehicle 10, such as a wheeled motor vehicle, is generally illustrated as having a vehicle body 12 generally defining a cabin interior, also referred to as a passenger compartment 15. The passenger compartment 15 typically includes a passenger seating arrangement including a front row of seats having a driver's seat 26 on the left side and a passenger seat 28 on the right side. The driver's seat 26 is generally located behind a steering wheel. A trim panel in the form of an instrument panel, also referred to as a dashboard 30, generally extends forward of the first row of seats and extends forward of the passenger seat 28 and may further extend forward of the driver's seat 26.

[0020] The motor vehicle 10 is configured such that the body 12 has a driver-side door 14 and a passenger-side door 16 that allow entry and exit from the motor vehicle 10. The body 12 also includes a roof 18 and a windshield 20 that extends generally between left and right support pillars 22 and 24 and between the instrument panel 30 on the lower side and the roof 18 on the upper side. The windshield 20 is typically made of laminated glass and provides a relatively large viewing area over the front end of the passenger compartment 15.

[0021] The motor vehicle 10 is further shown equipped with an airbag system 34 configured as a passenger airbag system, which is shown, in one example, located within the instrument panel 30 on the right passenger side, generally in front of the passenger seat 28 with respect to the vehicle. The vehicle 10 typically includes additional airbag systems for the driver and other passengers. The airbag system 34 is generally integrated into the instrument panel 30 on the right passenger side of the vehicle 10. The airbag system 34 typically includes an inflatable airbag that is inflated with gas generated during deployment. The airbag system 34 has an airbag deployment door 36 that is shown extending flush over a portion of the instrument panel 30 prior to deployment.When the airbag is deployed, the airbag deployment flap 36 opens to allow inflation and release of the airbag.

[0022] With reference to Fig. 2, the airbag deployment door 36 is shown in an open, fully deployed, or inflated position following deployment of the airbag system 34. As illustrated, the airbag deployment door 36 is generally formed from a panel integrally formed as part of a trim panel, particularly as part of the instrument panel 30, which is scored with reduced thickness portions 48A, 48B, and 48C at a Y-shaped score line 48. The score line 48 defines three distinct panels, i.e., a first panel 40, a second panel 42, and a third panel 44. The score line 48 serves as weakened crease lines extending generally in a Y shape, with portion 48C forming a base leg and portions 48A and 48B forming arms extending to the lateral corners.During deployment, the score line 48 allows the first, second, and third panels 40, 42, and 44 to rotate and buckle around the airbag during deployment to slow the speed of movement of the airbag deployment door 36 and reduce the contact force of the airbag deployment door 36 with the windshield 20.

[0023] With reference to Fig. 3, the airbag deployment door 36 is further illustrated as having a first hinge 46 formed along a vehicle forward side of the airbag deployment door 36 and connected along one edge to the instrument panel 30. The first hinge 46 may, for example, include a thin line of reduced thickness material forming a living hinge. The living hinge 46 may include a downwardly angled portion that bends to pivot upwardly during deployment to allow the airbag deployment door 36 to swing upward and forward with respect to the vehicle. The vehicle rearward side of the airbag door 36 includes a reduced thickness score line 50 that is sufficiently thin in thickness and configured to open out from the instrument panel 30 upon airbag deployment.As such, the portion of the airbag door 36 located rearward of the vehicle opens and pivots forward of the vehicle about the first hinge 46 toward the windshield 20 during airbag deployment. The score line 48 allows each of the first, second, and third panels 40, 42, and 44 to bend and buckle around the airbag when the airbag is deployed. It should be understood that the airbag deployment door 36 may be integrally formed as a portion of the instrument panel 30.

[0024] The airbag deployment flap 36 has reduced thickness portions 49A and 49B extending between the first hinge 46 at opposite ends and thick portions 51A and 51B of the instrument panel 30, which are further Fig. 3A. The reduced-thickness portions 49A and 49B are arcuate and allow the airbag deployment door 36 to rotate and open along the reduced-thickness portions 49A and 49B during airbag deployment. The thick portions 51A and 51B may have the same thickness as the instrument panel 30 and serve to slow the rotational movement of the airbag deployment door 36 during deployment. The score lines may have a reduced thickness, as illustrated by the score line 48B in Fig. 3B. The reduced thickness may be 50%-70% of the thickness of the instrument panel 30, according to one example.

[0025] Each of the first, second, and third panels 40, 42, and 44 of the airbag deployment door 36 is further illustrated as having a plurality of perforations 70 formed therein. The perforations 70 may include circular holes extending at least partially into or completely through the airbag deployment door 36. The perforations 70 allow for a reduced weight of the first, second, and third panels 40, 42, and 44, and thus a reduced overall weight of the airbag deployment door 36. It should be understood that one of a plurality of perforations of various sizes and shapes may be formed in each of the first, second, and third panels 40, 42, and 44, respectively, to reduce weight.

[0026] With reference to Fig. 4, the airbag system is further shown in relation to a deployed airbag deployment door 36 relative to the windshield 20. The airbag system includes an airbag 62 shown stowed within an airbag well 60. A pressurized gas is generated and released during airbag deployment to inflate the airbag and force it upwardly within the airbag well 60 into contact with the airbag deployment door 36. The force of the inflating airbag on the airbag deployment door 36 causes the airbag deployment door 36 to open about the tear seam 50 located rearward of the vehicle and pivot upwardly and forwardly of the vehicle about the first hinge 46 to a position, as shown by the dashed lines, surrounding the inside of the windshield 20 in Fig.4. The score line 48 with the reduced thickness portions 48A, 48B and 48C advantageously allows the airbag deployment door 36 to rotate and buckle during deployment, thereby reducing or minimizing the force transmitted to the windshield 20.

[0027] Accordingly, the motor vehicle 10 is equipped with an instrument panel 30 having an airbag deployment door 36 configured with at least three panels 40, 42, and 44 interconnected by a Y-shaped score line 48 and coupled to the instrument panel 30 via a first hinge 46. The score lines advantageously allow the three panels 40, 42, and 44 to rotate and buckle, thereby reducing the force of the airbag deployment door 36 acting on the windshield 20 during airbag deployment.

[0028] It is to be understood that variations and modifications may be made to the foregoing structure without departing from the concepts of the present disclosure, and it is further understood that such concepts are intended to be covered by the following claims unless these claims expressly state otherwise by their language.

[0029] According to the present invention, there is provided an airbag deployment door for a motor vehicle, comprising: a panel; a hinge formed along one side of the panel, the hinge configured to be coupled to a panel on the vehicle to allow the panel to pivot; a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag; and a score line extending through the panel in the form of a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag.

[0030] According to one embodiment, the airbag deployment flap is configured to be coupled to an instrument panel in the motor vehicle.

[0031] According to one embodiment, the score line comprises a reduced thickness of the panel. According to one embodiment, the tear seam comprises a reduced thickness of an instrument panel.

[0032] According to one embodiment, the first hinge comprises a dashboard material with reduced thickness.

[0033] According to one embodiment, the airbag deployment flap is intended for a passenger airbag located in front of a passenger seat in the motor vehicle.

[0034] According to one embodiment, the airbag door is located in an instrument panel relative to the vehicle behind a vehicle windshield, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag.

[0035] According to the present invention, there is provided an instrument panel for a motor vehicle, comprising: an upper trim panel configured to be mounted to the motor vehicle; an airbag deployment door comprising: a panel; a hinge formed along one side of the panel, the hinge configured to be coupled to a panel on the vehicle to allow the panel to pivot; a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag; and a score line extending through the panel in the form of a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag.According to one embodiment, the airbag deployment flap in the vehicle is formed integrally with the dashboard.

[0036] According to one embodiment, the score line comprises a reduced thickness of the panel. According to one embodiment, the tear seam comprises a reduced thickness of the instrument panel.

[0037] According to one embodiment, the first hinge comprises a dashboard material with reduced thickness.

[0038] According to one embodiment, the airbag deployment flap is intended for a passenger airbag flap located in front of a passenger seat in a motor vehicle.

[0039] According to one embodiment, the instrument panel is located behind a vehicle windshield with respect to the vehicle, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag.According to the present invention, a vehicle is provided comprising: a windshield; an instrument panel located behind and / or below the windshield with respect to the vehicle; and an airbag system comprising: an airbag; and an airbag deployment door comprising: a panel; a hinge coupling one side of the panel to the instrument panel, the hinge configured to allow the panel to pivot during deployment of the airbag; a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag; and a score line extending through the panel in the form of a generally Y-shape to form first, second, and third panel members, the score lines allowing the first, second, and third panel members to buckle during deployment of the airbag.

[0040] According to one embodiment, the airbag deployment flap is formed integrally with the dashboard.

[0041] According to one embodiment, the score line comprises a reduced thickness of the panel. According to one embodiment, the tear seam comprises a reduced thickness of the instrument panel.

[0042] According to one embodiment, the first hinge comprises a dashboard material with reduced thickness.

[0043] According to one embodiment, the airbag deployment flap is intended for a passenger airbag flap located in front of a passenger seat in the vehicle.

Claims

[1] Airbag deployment flap for a motor vehicle, the airbag deployment flap comprising: a plate; a hinge formed along a side of the panel, the hinge configured to be coupled to a panel on the vehicle to allow the panel to pivot; a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag; and a score line extending through the panel in the form of a generally Y-shape to form first, second and third panel members, the score lines allowing the first, second and third panel members to buckle during deployment of the airbag. [2] The airbag deployment door of claim 1, wherein the airbag deployment door is configured to be coupled to an instrument panel in the motor vehicle. [3] The airbag deployment door of claim 1, wherein the score line comprises a reduced thickness of the plate. [4] The airbag deployment door of claim 1, wherein the tear seam comprises a reduced thickness of an instrument panel. [5] The airbag deployment door of claim 4, wherein the first hinge comprises a reduced thickness instrument panel material. [6] Airbag deployment flap according to claim 1, wherein the airbag deployment flap is intended for a passenger airbag located in front of a passenger seat in the motor vehicle. [7] The airbag deployment door of claim 1, wherein the airbag door is located in an instrument panel behind a vehicle windshield with respect to the vehicle, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag. [8] Dashboard for a motor vehicle, the dashboard comprising: an upper fairing panel configured to be mounted to the motor vehicle; an airbag deployment flap, comprising: a plate; a hinge formed along a side of the panel, the hinge configured to be coupled to a panel on the vehicle to allow the panel to pivot; a tear seam extending on an opposite side of the panel, the tear seam configured to open during deployment of an airbag; and a score line extending through the panel in the form of a generally Y-shape to form first, second and third panel members, the score lines allowing the first, second and third panel members to buckle during deployment of the airbag. [9] The instrument panel of claim 8, wherein the airbag deployment door in the vehicle is formed integrally with the instrument panel. [10] The instrument panel of claim 8, wherein the score line comprises a reduced thickness of the panel. [11] The instrument panel of claim 8, wherein the tear seam comprises a reduced thickness of the instrument panel. [12] The instrument panel of claim 8, wherein the first hinge comprises a reduced thickness instrument panel material. [13] The instrument panel of claim 8, wherein the airbag deployment door is for a passenger airbag door located in front of a passenger seat in a motor vehicle. [14] The instrument panel of claim 8, wherein the instrument panel is located behind a vehicle windshield with respect to the vehicle, and wherein the airbag deployment door is configured to contact the windshield during deployment of the airbag.

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