Dashboard support system for dual-horizon display with enclosed passenger-side airbag flap

Abstract

A vehicle dashboard includes a substrate and an airbag flap assembly, which has one or more gaps forming openings. The mounting substrate incorporates a predetermined breaking point beneath the airbag flap assembly. An upper trim panel extends over a portion of the substrate and the airbag flap assembly. Foam is positioned between the substrate and the upper trim panel. An airbag module is positioned beneath the predetermined breaking point. When it deploys, the airbag causes the predetermined breaking point and the foam above the airbag flap assembly to rupture.

Description

AREA OF REVELATION

[0001] The present disclosure relates generally to a dashboard for vehicles and in particular to a dashboard with an encapsulated passenger-side airbag flap. GENERAL STATE OF THE ART

[0002] Various vehicle airbag systems have been developed so far. Airbags can be positioned in a front section of the passenger compartment in front of the driver and / or passenger side of the vehicle. SUMMARY OF THE REVELATION

[0003] One aspect of the present disclosure is a vehicle dashboard. The dashboard includes a polymer substrate having a leading edge, a trailing edge, and a horizontal section between the leading and trailing edges. The horizontal section comprises a driver's side and a passenger's side. The dashboard further includes a metal airbag flap assembly having a ring structure attached to the upper surface of the horizontal section of the polymer substrate on the passenger side. The ring structure extends around a central opening of the ring structure, and at least one flap extends over a portion of the central opening. The flap is hinged to the ring structure and forms a gap between the flap and the ring structure. The polymer substrate includes a shear rib located beneath the flap of the metal passenger airbag flap assembly.The instrument panel further includes an upper trim panel comprising at least one layer of cover material extending over the horizontal portion of the polymer substrate and the metal airbag flap assembly. Foam is positioned between the polymer substrate and the upper trim panel. The foam encapsulates the metal airbag flap assembly, thus placing foam between the metal airbag flap assembly and the upper trim panel. The instrument panel further includes an airbag module positioned beneath the tear strip. When the airbag deploys, it ruptures the tear strip and the foam above the metal airbag flap assembly, causing the flap to move upward around the hinge. This tears the upper trim panel, allowing the airbag to expand and deploy over the upper trim panel.

[0004] Embodiments of the first aspect of the present disclosure may optionally include any one or a combination of the following features: - The hinge optionally includes metal configured to bend as the flap moves upwards when the airbag deploys. - The flap and the ring structure can be formed in one piece from a single sheet of metal. - The flap can include a first flap and a second flap can be connected to the ring structure, causing the edges of the first and second flaps to rotate upwards and away from each other relative to the ring structure when the airbag deploys. - The first flap and the second flap can be connected to the ring structure by metal hinges which are U-shaped in cross-section with upwardly opening channels. - The predetermined breaking point can have a first thickness, and an area of ​​the polymer substrate surrounding the predetermined breaking point can have a second thickness that is greater than the first thickness. - The predetermined breaking point can be formed integrally with the area of ​​the polymer substrate surrounding the predetermined breaking point. - The ring structure can be attached to the area of ​​the polymer substrate surrounding the predetermined breaking point by mechanical fasteners. The leading edge of the polymer substrate may have a contour configured to match the contour of a lower section of a vehicle windshield. The instrument panel may include a curved panel extending along the leading edge of the polymer substrate at a junction between the curved panel and the polymer substrate. The curved panel may have a central section incorporating an angled stepped surface facing upward and rearward. The instrument panel may further include a vertical dual-horizon display extending along the leading edge of the polymer substrate. The dual-horizon display may have a concave rear surface extending upward in front of the driver and passenger sides of the horizontal section of the polymer substrate. - The double-horizon display may include a perpendicular convex front surface spaced away from the angled step surface of the curved board to form a gap between them which is V-shaped in cross-section. - The dashboard may include a frontal structure extending along the trailing edge of the polymer substrate. The frontal structure may include an upward-facing upper surface extending between a leading and trailing edge of the upper surface. The frontal structure may further include a forward-facing stepped surface extending between the upper trim and the leading edge of the upper surface of the frontal structure. - The airbag module can be configured to deploy the airbag upwards and backwards, causing the airbag to move upwards and backwards over the step surface and the upper surface of the frontal structure. - The upper surface of the frontal structure may have a convex curvature and the rear edge of the upper surface of the frontal structure may be lower than the front edge of the upper surface of the frontal structure.

[0005] According to a second aspect of the present disclosure, a vehicle dashboard comprises a substrate having a leading edge, a trailing edge, and a central section between the leading and trailing edges. An airbag flap assembly has a base structure and at least one flap connected to the base structure by a hinge. An upper cover extends over at least one section of the substrate and over the airbag flap assembly. Foam is arranged between the substrate and the upper cover and between the airbag flap assembly and the upper cover.An airbag module is positioned beneath the substrate, causing an airbag of the airbag module to expand and rupture the substrate and the foam above the airbag flap assembly as the airbag module deploys, causing at least one flap to move upwards around the hinge, thereby tearing the upper trim to allow the airbag to expand and deploy above the upper trim.

[0006] Embodiments of the second aspect of the present disclosure may optionally include any one or a combination of the following features: - The substrate may include a predetermined breaking point located under the flap of the airbag flap assembly. - The at least one flap and the basic structure can be formed in one piece from a single sheet of metal. - The at least one valve can include a first and a second valve. - The basic structure can include a ring structure that extends around the first and second flaps. The first and second flaps can be pivotally connected to the ring structure, causing the edges of the first and second flaps to rotate upwards and away from each other relative to the ring structure when the airbag deploys.

[0007] According to a third aspect of the present disclosure, a vehicle comprises a body having a passenger compartment with a front driver-side compartment and a front passenger-side compartment. A main dashboard substrate is attached to the body and positioned in front of the front driver-side compartment and in front of the front passenger-side compartment. A support substrate is attached to a top surface of the main dashboard substrate, the support substrate having a leading edge, a trailing edge, and a central section between the leading and trailing edges, the central section comprising a driver's side and a passenger's side. An airbag flap assembly has a base structure attached to the support substrate on the passenger side thereof. The airbag flap assembly includes at least one flap connected to the base structure by a hinge.The mounting substrate includes a predetermined breaking point located beneath the flap of the airbag flap assembly. An upper cover extends over the central section of the mounting substrate and over the airbag flap assembly. Foam is positioned between the mounting substrate and the upper cover, and between the airbag flap assembly and the upper cover. An airbag module is positioned beneath the predetermined breaking point. As the airbag module deploys, its airbag tears through the breaking point and the foam covering the airbag flap assembly, causing the at least one flap to pivot upward around the hinge. This tears the upper cover, allowing the airbag to expand and deploy over the upper cover.

[0008] Embodiments of the third aspect of the present disclosure may optionally include any one or a combination of the following features: - The vehicle may include a front structure that extends along the trailing edge of the support substrate. - The frontal structure may include an upward-pointing upper surface that extends between a front and a rear edge of the upper surface. - The front structure may further include a forward and upward angled stepped surface extending between the upper cladding and the leading edge of the upper surface of the front structure.

[0009] These and other features, advantages and functions of the present invention will be more easily understood and apparent to the person skilled in the art by reference to the following description, the claims and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following applies to the drawings: Fig. Figure 1 is an isometric view of a vehicle dashboard according to one aspect of the present disclosure; Fig. Figure 2 is a stretched perspective view of the dashboard of the Fig. 1; Fig. 3A is a partially fragmentary isometric view of the top side of an airbag flap assembly and substrate; Fig. 3B is a partially fragmentary isometric view of a bottom side of the substrate and the airbag flap assembly of the Fig. 3A; Fig. Figure 4 is a cross-sectional view of the dashboard. Fig. 1 along line IV-IV of the Fig. 1; Fig. 4A is an enlarged fragmentary view of a section of the dashboard of the Fig. 4; Fig. Figure 5 is a cross-sectional view of the dashboard of the Fig. 4, which shows the deployment of an airbag; Fig. Figure 6 is a partially schematic view showing the manufacture of an instrument panel according to one aspect of the present disclosure; Fig. Figure 7 is a partially schematic view showing the manufacture of an instrument panel according to one aspect of the present disclosure; and Fig. Figure 8 is a partially fragmentary enlarged view of a section of the Fig. 7. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0011] A detailed reference will now be made to the present preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Where possible, the same reference numerals are used in the drawings to denote identical or similar parts. In the drawings, the structural elements depicted are not to scale, and certain components have been enlarged relative to the other components for the purpose of emphasis and clarity.

[0012] In accordance with the requirements, detailed embodiments of the present disclosure are disclosed herein; however, it is understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various and alternative forms. The figures do not necessarily represent a detailed embodiment; some schematic representations may be enlarged 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 the person skilled in the art the diverse applications of the present invention.

[0013] Within the context of this description, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and derivatives refer to the concepts in their orientation in Fig. 1. It is understood, however, that the concepts can assume various alternative orientations unless expressly stated otherwise. It is also understood that the specific devices and processes illustrated in the accompanying drawings and described in the following description are merely exemplary embodiments of the concepts according to the invention as defined in the accompanying claims. Thus, specific dimensions and other physical properties relating to the embodiments disclosed herein are not to be considered limiting unless expressly stated otherwise in the claims.

[0014] The embodiments illustrated herein consist mainly of combinations of process steps and equipment components relating to an instrument panel. Accordingly, the equipment components and process steps are, where appropriate, represented in the drawings by conventional symbols, showing only those specific details relevant to understanding the embodiments of this disclosure, so as not to obscure the disclosure with details that are readily apparent to the person skilled in the art from the description in this document. Furthermore, identical reference numerals in the description and the drawings represent identical elements.

[0015] In the sense used herein, the terms "or" and "and / or," when used in a list of two or more elements, mean that each of the listed elements may be used individually, or any combination of two or more of the listed elements may be used. For example, if a composition or device is described as containing or comprising components A, B, or C, the composition or device may contain (include) 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. If a composition or device is described as containing or comprising components A and / or B and / or C, the composition or device may contain (include) 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.

[0016] In this writing, reference terms such as first and second, upper and lower, and the like are used merely to distinguish one unit or action from another, without necessarily requiring or implying any actual relationship or order of such unit or action between such units or actions. It is intended that the terms "includes," "comprising," "incorporating," or any other variation thereof cover a non-exclusive inclusion such that a process, procedure, object, or facility which includes or incorporates an enumeration of elements may include not only those elements but may also include other elements not expressly listed or inherent in such process, procedure, object, or facility. An element that "includes..." or "contains..."The presence of “a” does not, without further limitations, preclude the presence of additional identical elements in the process, procedure, subject matter or facility that includes the element.

[0017] In the sense used herein, the term "approximately" means that quantities, sizes, formulations, parameters, and other quantities and properties are not, and need not be, exact, but may be approximate and / or larger or smaller if desired, and may reflect tolerances, conversion factors, rounding, measurement errors, and the like, and other factors known to the person skilled in the art. When the term "approximately" is used to describe a value or an endpoint of a range, the disclosure should be understood as including the specific value or endpoint to which reference is made. Regardless of whether a numerical value or an endpoint of a range contains "approximately" in the description, the numerical value or the endpoint of a range is intended to include two embodiments: one modified by "approximately" and one not modified by "approximately".It is further understood that the endpoints of each of the areas are significant both with respect to the other endpoint and independently of the other endpoint.

[0018] The terms "essentially," "substantially," and variations thereof are used in this context to indicate that a described feature is equal to or nearly equal to a value or description. For example, a "substantially flat" surface means that a surface is flat or nearly flat. Furthermore, "substantially" means that two values ​​are equal to or nearly equal to each other. In some embodiments, "substantially" may denote values ​​within approximately 10% of each other, such as within approximately 5% of each other or within approximately 2% of each other.

[0019] In the present context, the terms "the", "a", "a", or "a" mean "at least one" and should not be limited to "just one" unless expressly stated otherwise. Thus, for example, a reference to "one component" includes embodiments having two or more such components, unless the context clearly indicates otherwise.

[0020] With reference to the Fig. 1 and Fig. 2 comprises a dashboard 1 for a vehicle according to one aspect of the present disclosure, a mounting substrate 2, a metal airbag flap assembly 3 which, in the assembled state, is covered by foam 4 (dashed lines 3A), and an upper cover 5 over the foam 4. When the dashboard 1 is assembled, an airbag module 30 ( Fig. 4) positioned under the metal airbag flap assembly 3, causing flaps 20A and 20B of the metal airbag flap assembly 3 to pivot upwards when the airbag module 30 is actuated ( Fig. 5) The substrate 2 can be attached to a main substrate 6 by means of supports 7. When assembled, the substrate 2, the metal flap assembly 3, the foam 4, and the upper cover 21 generally form a support structure 21. The main substrate 6 can be attached to a vehicle body 13 of a motor vehicle in front of a first row of seats R, which includes a seat 17A on the driver's side and a seat 17B on the passenger's side. A steering wheel 19 can be positioned in front of the driver's seat 17A. As discussed in more detail below, the instrument panel 1 can also have a front structure 8 which, when assembled, extends along a trailing edge 9 of the substrate 2. The instrument panel 1 can also include a dual-horizon display 11 and a sound-amplifying panel 10 that supports loudspeakers (not shown).

[0021] With reference to the Fig. 1, Fig. 2 and Fig. 4 The sound-dampening plate 10 can include openings 42 for mounting loudspeakers (not shown), which can be positioned outside opposite ends 44 of the double-horizon display 11, so that sound from the loudspeakers is not blocked by the double-horizon display 11. The sound-dampening plate 10 includes a central section 46 with a concave curved surface 48 facing upwards and backwards. The surface 48 is spaced from the surface 50 of the display 11 to form a gap 52, which is generally V-shaped in cross-section, as shown in Fig. Figure 4 shows that surfaces 48 and 50 can form an angle 9 of approximately 20–60°. A lower edge 54 of the plate 10 extends along a joint 56 formed by the engagement of the lower edge 54 with an upper cladding 5 of the substrate 2. In general, the lower edge 54 and the joint 56 exhibit a curvature (in plan view) corresponding to the leading edge 12 ( Fig. 2) of the substrate 2 corresponds. An upper edge 55 of the sound-dampening plate 10 can be adjacent to a de-icing substrate structure 58 ( Fig. 4) be positioned having one or more openings 60 configured to direct de-icing air onto a lower surface 23 of a windshield 25.

[0022] With renewed reference to Fig. 2 The substrate 2 can comprise a polymer material and can have a curved leading edge 12, a trailing edge 9, and a horizontal section 14 extending between the leading edge 12 and the trailing edge 9. The leading edge 12 can be curved to conform to the contour of a lower section of a windshield 25 ( Fig. 4) of a vehicle. The substrate 2 may include a predetermined breaking rib 32 and a region 34 surrounding the predetermined breaking rib 32. The predetermined breaking rib 32 may have a reduced thickness relative to the thickness of the region 34 surrounding the predetermined breaking rib 32. A variety of grooves or slots 27 may be formed in the predetermined breaking rib 32, thereby reducing the strength of the substrate 2 over the flap assembly 3 to allow the flaps 20A, 20B to tear / rupture the substrate 2 when the airbag module 30 deploys. The predetermined breaking rib 32 is not limited to reduced thickness or slots 27 and may have reduced thickness and / or grooves or slots 27 to facilitate tearing by the flaps 20A, 20B. The predetermined breaking point 32 and the surrounding area 34 can be formed in one piece from polymer material.

[0023] With reference to the Fig. 3A and Fig. 3B can include the metal flap assembly 3, a ring structure 16 extending around a central opening 18 of the flap assembly 3, and flaps 20A and 20B movably connected to the ring structure 16 by hinges 22A and 22B, respectively. The hinges 22A and 22B can form upwardly opening U-shaped channels 26A, 26B (see also Fig. 4) The hinges 22A can pass through openings 88 ( Fig. 3A) extend into the predetermined breaking point 32 of the substrate 2. The flaps 20A and 20B can be spaced apart from the ring structure 16 to form a gap 24, and end edges 28A, 28B of the flaps 20A, 20B opposite the hinges 22A, 22B can be spaced apart to form a central gap 24A between the end edges 28A, 28B. As shown in Fig. As shown in Figure 4A, a section 4A of the foam 4 is arranged in a gap 40A between the metal flap assembly 3 (e.g., flaps 20A and 20B) and the upper cover 5. As described in more detail below in conjunction with the Fig. As discussed in Figures 6-8, during manufacturing a layer of material, such as paper or adhesive tape 35, is positioned on the flap assembly 3 (e.g., glued to the flap assembly 3) to prevent the foam 4 from entering the gaps 24 and 24A, thus preventing the space 40 between the flaps 20A, 20B and the predetermined breaking point 32 of the substrate 2 from being filled with foam. It is understood, however, that the adhesive tape 35 does not necessarily seal the gaps 24, 24A perfectly, and in some cases some foam 4 may enter the space 40. A fracture line 41 ( Fig. 4A) can be formed in the lower surface 5A of the upper cover 5 above the gap 24A between the edges 28A, 28B of the flaps 20A, 20B before the foam 4 is injected between the flap assembly 3 and the cover 5. After the foam 4 has been injected, a cut 43 is made in the foam 4 by inserting a knife 33 through an opening 21 in the substrate 2 and through the gap 24A. As described in more detail below in conjunction with Fig. As discussed in section 5, flaps 20A and 20B move upwards, tearing the cover 5 at the fracture line 41 and separating the foam 4 at the cut 43 when an airbag 68 of the airbag module 30 deploys. As in Fig. As shown in Figure 4, the airbag module 30 can be attached to a lower side 29 of the substrate 2 under the metal flap assembly 3 using bolts 36 welded to the ring structure 16 and extending through openings in flanges 31 of the airbag module 30. The bolts 36 engage in nuts 37, thereby inserting a section of the substrate 2 around the predetermined breaking point 32 between the ring structure 16 and the flanges 31 of the airbag module 30. The flaps 20A and 20B rotate upwards, as indicated by arrows “A” and “B” respectively. Fig. 4) shown when the airbag module 30 unfolds.

[0024] With renewed reference to Fig. 4 A front structure 8 extends along the rear edge 9 of the substrate 2. The front structure 8 includes an upward-facing surface 62 having a front edge 63 and a rear edge 64. A forward-facing step or ramp surface 66 of the front structure 8 extends between the edge 63 of the surface 62 and a rear section 67 of the upper cladding 5 of the substrate 2. The step or ramp surface 66 can be angled, thus facing both forward and upward, as shown in Fig. 4 shown.

[0025] With further reference to Fig. 5. The airbag 68 expands upwards and tears the predetermined breaking point 32 of the substrate 2 when the airbag module 30 deploys. The breaking point 32 can be torn along a central row 27A ( Fig. 4A) of openings 27, which are vertically aligned with the gap 24A between the outer edges 28A, 28B of the flaps 20A, 20B, break apart. The substrate 2 can also tear or bend along the outer row of slots 27 on the opposite side of the middle row 27A of slots 27. The expansion of the airbag 68 also tears the foam 4 along the cut 43 in the foam 4 ( Fig. 4) above the metal flap assembly 3. The expansion of the airbag 68 causes the flaps 20A and 20B of the flap assembly 3 and sections 45A, 45B of the foam 4 to pivot into the positions shown by dashed lines 70A and 70B, forming an opening 69 in the support structure 21. The upper trim 5 in the area above the flap assembly 3 tears along the fracture line 41, and sections 47A, 47B of the trim 5 also rotate with the flaps 20A, 20B. When it deploys, the airbag 68 expands upward and backward over the step or ramp surface 66 and over the upward-facing surface 62 of the front structure 8. The airbag module 30 can be configured to deploy the airbag 68 along a line “D” that is angled upwards and backwards, causing the airbag 68 to expand upwards and backwards as it deploys.The upper panel 5 of the support structure 21 can be positioned below the upper surface 62 of the front structure 8 to allow a driver and front passenger in a front row of a vehicle to view the curved display surface 72 of the dual-horizon display 11, and the ramp surface 66 and the upper surface 62 of the front structure 8 guide the airbag 68 upwards and backwards when the airbag 68 expands.

[0026] With further reference to the Fig. 6-8 During manufacturing, the flap assembly 3 is first attached using suitable fastening elements, such as rivets 38, which pass through openings 39 ( Fig. 3A) in the metal flap assembly 3 and openings in the substrate 2, to which the substrate 2 is attached. A material layer 35 is then positioned on or over the flap assembly 3. The material layer 35 can, for example, comprise a rectangular strip of adhesive tape or other suitable material that is adhered to the metal flap assembly 3. The layer 35 ensures that the foam 4 does not fill the space 40 between the flaps 20A and 20B and the substrate 2.

[0027] With renewed reference to Fig. 6 A tool 75 with an upper and a lower part 75A and 75B is used to produce the support structure 21. The upper cover 5 is first positioned in a cavity 76B of a lower tool part 75B, and the substrate 2 is then positioned against the cover 5. The upper cover 5 can be thin and flexible, allowing it to conform to the counterpart of the cavity 76B. The substrate 2 can be at least somewhat rigid, creating a space 86 ( Fig. 7) is formed between the cover 5 and the substrate 2 when the substrate 2 is positioned above the cover 5 on the lower tool part 75B. The substrate 2 may include an opening 84 configured to align with a foam injection port 85 of the upper tool part 75. After the cover 5 and the substrate 2 are positioned in the cavity 76B of the lower tool part 75B ( Fig. 6) The upper and lower tool parts 75A and 75B are brought together as shown in Fig. Figure 7 shows the foam injection port 85 being received in the opening 84 of the substrate 2. Liquid foam 82 from a foam source 78 is then injected through the opening 84 of the substrate 2 into the cavity 86 between the substrate 2 and the cover 5. The foam can be, for example, polyurethane foam or another suitable foam. The upper tool part 75A has a tool surface 76A configured to precisely match a contour of the substrate 2, thereby maintaining the shape of the substrate 2 when the liquid foam 82 is injected and while the foam cures. The tool parts 75A and 75B can be separated after the foam 4 has cured, and the support structure 21 is then removed from the tool 75.

[0028] With further reference to Fig. As noted above, the cladding 5 can include a fracture line 41 on surface 5A of the cladding 5. The fracture line 41 is formed on the upper cladding 5 before the foam 4 is injected into the space 86 between the substrate 2 and the cladding 5. After the foam 4 has solidified, a knife 33 can be used to form a cut 43 in the foam 4 by passing through a central row 27A of openings 27 in the substrate 2 and through the gap 24A between the flaps 20A and 20B. As previously described in conjunction with Fig. As discussed in section 5, the fracture line 41 and the cut 43 facilitate the tearing of the foam 4 and the trim 5 when the flaps 20A and 20B pivot into an open position while the airbag 68 deploys.

[0029] It is understood that variations and modifications to the aforementioned structure may be made without deviating from the concepts of the present invention, and it is further understood that such concepts are to be covered by the following patent claims, unless these patent claims expressly provide otherwise by their wording.

[0030] According to the present invention, a dashboard for vehicles is provided, comprising: a polymer substrate having a leading edge, a trailing edge, and a horizontal section between the leading and trailing edges, the horizontal section comprising a driver's side and a passenger's side; a metal airbag flap assembly comprising a ring structure attached to a top surface of the horizontal section of the polymer substrate on a passenger's side thereof, the ring structure extending around a central opening of the ring structure, the metal airbag flap assembly comprising at least one flap extending over a section of the central opening, the flap being connected to the ring structure by a hinge; and the polymer substrate comprising a predetermined breaking point arranged beneath the flap of the metal airbag flap assembly;an upper cover comprising at least one layer of covering material extending over a section of the polymer substrate and over the metal airbag flap assembly; foam arranged between the polymer substrate and the upper cover and between the metal airbag flap assembly and the upper cover; and an airbag module positioned below the breakaway rib, whereby, as the airbag module inflates, an airbag of the airbag module expands and ruptures the breakaway rib and the foam over the metal airbag flap assembly, causing the at least one flap to move upward around the hinge, thereby tearing the upper cover to allow the airbag to expand and inflate over the upper cover.

[0031] According to one embodiment, the hinge comprises metal configured to bend as the flap moves upwards when the airbag deploys.

[0032] According to one embodiment, the flap and the ring structure are formed in one piece from a single sheet of metal.

[0033] According to one embodiment, the flap comprises a first flap; and comprising: a second flap connected to the ring structure, whereby edges of the first and second flaps rotate upwards and away from each other relative to the ring structure when the airbag deploys.

[0034] According to one embodiment, the first flap and the second flap are connected to the ring structure by metal hinges which are U-shaped in cross-section with upwardly opening channels.

[0035] According to one embodiment, the predetermined breaking point comprises a plurality of elongated grooves and / or slots in the polymer substrate surrounding the predetermined breaking point, which has a second thickness that is greater than the first thickness.

[0036] According to one embodiment, the predetermined breaking point is formed integrally with the area of ​​the polymer substrate that surrounds the predetermined breaking point.

[0037] According to one embodiment, the ring structure is attached to the area of ​​the polymer substrate surrounding the predetermined breaking point by mechanical fastening elements.

[0038] According to one embodiment, the leading edge of the polymer substrate has a contour configured to match the contour of a lower section of a vehicle windshield; and comprising: a curved board extending along the leading edge of the polymer substrate at a junction of the curved board and the polymer substrate, the curved board having a central section comprising an angled step surface facing upward and rearward; and a vertical double-horizon indicator extending along the leading edge of the polymer substrate, the double-horizon indicator having a concave rear surface extending upward in front of the driver and passenger sides of the horizontal section of the polymer substrate.

[0039] According to one embodiment, the double-horizon display includes a perpendicular convex front surface that is spaced apart from the angled step surface of the curved board to form a gap between them which is V-shaped in cross-section.

[0040] According to one embodiment, the invention is further characterized by the following: an end structure extending along the trailing edge of the polymer substrate, wherein the end structure includes an upwardly pointing upper surface extending between a front and a trailing edge of the upper surface, wherein the end structure further includes a ramp surface extending at an angle between the upper cladding and the front edge of the upper surface, whereby the ramp surface points upwards and forwards.

[0041] According to one embodiment, the airbag module is configured to unfold the airbag upwards and backwards, causing the airbag to move upwards and backwards over the ramp surface and the upper surface of the frontal structure.

[0042] According to one embodiment, the upper surface of the frontal structure has a convex curvature and the trailing edge of the upper surface of the frontal structure is lower than the first edge of the upper surface of the frontal structure.

[0043] According to the present invention, a dashboard for vehicles is provided, comprising: a substrate having a front edge, a rear edge, and a central section between the front and rear edges; an airbag flap assembly having a base structure and at least one flap connected to the base structure by a hinge; an upper cover extending over at least one section of the substrate and over the airbag flap assembly; and foam arranged between the substrate and the upper cover and between the airbag flap assembly and the upper cover.and an airbag module positioned beneath the substrate, whereby an airbag of the airbag module expands and ruptures the substrate and the foam above the airbag flap assembly when the airbag module deploys, causing the at least one flap to move upwards around the hinge, thereby tearing the upper trim to allow the airbag to expand and deploy above the upper trim.

[0044] According to one embodiment, the substrate includes a predetermined breaking point that is located under the flap of the airbag flap assembly.

[0045] According to one embodiment, the flap and the predetermined breaking point form a gap between them that is not filled with foam.

[0046] According to one embodiment, the at least one flap and the base structure are formed in one piece from a single sheet of metal.

[0047] According to one embodiment, the at least one flap comprises a first and a second flap; and wherein: the base structure comprises a ring structure extending around the first and second flaps, wherein the first and second flaps are pivotably connected to the ring structure, thereby spacing the edges of the first and second flaps apart to form an elongated gap; the foam includes a perpendicular cut aligned vertically with the elongated gap, whereby the foam separates along the perpendicular cut when the first and second flaps twist open as the airbag deploys.

[0048] According to the present invention, a vehicle is provided comprising: a body comprising a passenger compartment with a front driver-side compartment and a front passenger-side compartment; a main dashboard substrate attached to the body and positioned in front of the front driver-side compartment and in front of the front passenger-side compartment; a support substrate attached to a top surface of the main dashboard substrate, the support substrate having a leading edge, a trailing edge, and a central section between the leading and trailing edges, the central section comprising a driver's side and a passenger's side; an airbag flap assembly comprising a base structure attached to the support substrate on the passenger side thereof, the airbag flap assembly comprising at least one flap connected to the base structure by a hinge;and wherein the support substrate includes a predetermined breaking point located below the flap of the airbag flap assembly; an upper cover extending over the central section of the support substrate and the airbag flap assembly; foam located between the support substrate and the upper cover and between the airbag flap assembly and the upper cover; and an airbag module positioned below the predetermined breaking point, wherein, when the airbag module deploys, an airbag of the airbag module tears the predetermined breaking point and the foam above the airbag flap assembly, causing the at least one flap to pivot upwards about the hinge, thereby tearing the upper cover to allow the airbag to expand and deploy above the upper cover.

[0049] According to one embodiment, the invention is further characterized by the following: an end structure extending along the rear edge of the support substrate, wherein the end structure includes an upwardly pointing upper surface extending between a front and a rear edge of the upper surface, wherein the end structure further includes a forward and upwardly pointing angled step surface extending between the upper cladding and the front edge of the upper surface.

Claims

[1] Dashboard for vehicles, the dashboard comprising: a polymer substrate having a leading edge, a trailing edge and a horizontal section between the leading and trailing edges, wherein the horizontal section includes a driver's side and a passenger's side; a metal airbag flap assembly comprising a ring structure attached to an upper surface of the horizontal section of the polymer substrate on the passenger side thereof, the ring structure extending around a central opening of the ring structure, the metal airbag flap assembly comprising at least one flap extending over a section of the central opening, the flap being connected to the ring structure by a hinge; and wherein the polymer substrate includes a predetermined breaking point located below the flap of the metal airbag flap assembly; an upper cladding comprising at least one layer of covering material extending over a section of the polymer substrate and over the metal airbag flap assembly; Foam that is positioned between the polymer substrate and the upper trim panel and between the metal airbag flap assembly and the upper trim panel; and an airbag module positioned below the shear strip, causing an airbag of the airbag module to expand and break through the shear strip and the foam over the metal airbag flap assembly as the airbag module deploys, causing at least one flap to move upwards around the hinge, thereby tearing the upper trim to allow the airbag to expand and deploy over the upper trim. [2] Dashboard according to claim 1, wherein: The hinge includes metal that is configured to bend as the flap moves upwards when the airbag deploys. [3] Dashboard according to claim 1 or claim 2, wherein: The flap and the ring structure are formed in one piece from a single sheet of metal. [4] Dashboard according to one of claims 1-3, wherein: the flap includes a first flap; and including: a second flap connected to the ring structure, causing the edges of the first and second flaps to rotate upwards and away from each other relative to the ring structure when the airbag deploys. [5] Dashboard according to claim 4, wherein: The first flap and the second flap are connected to the ring structure by metal hinges which are U-shaped in cross-section with upwardly opening channels. [6] Dashboard according to one of claims 1-5, wherein: The predetermined breaking point includes a multitude of elongated grooves and / or slots in the polymer substrate surrounding the predetermined breaking point, which has a second thickness that is greater than the first thickness. [7] Dashboard according to one of claims 1-6, wherein: The predetermined breaking point is formed integrally with the area of ​​the polymer substrate that surrounds the predetermined breaking point. [8] Dashboard according to one of claims 1-7, wherein: The ring structure is attached to the area of ​​the polymer substrate surrounding the predetermined breaking point by mechanical fastening elements. [9] Dashboard according to any one of claims 1-8, wherein: the leading edge of the polymer substrate has a contour configured to match the contour of a lower section of a vehicle windshield; and comprising: a curved board extending along the leading edge of the polymer substrate at a junction between the curved board and the polymer substrate, the curved board having a central section incorporating an angled step surface facing upwards and backwards; and a vertical double-horizon indicator extending along the leading edge of the polymer substrate, wherein the double-horizon indicator has a concave rear surface extending upwards in front of the driver and passenger side of the horizontal section of the polymer substrate. [10] Dashboard according to claim 9, wherein: The double-horizon display includes a perpendicular convex front surface that is spaced apart from the angled step surface of the curved board to form a gap between them which is V-shaped in cross-section. [11] Dashboard according to any one of claims 1-10, comprising: a frontal structure extending along the trailing edge of the polymer substrate, wherein the frontal structure includes an upward-facing upper surface extending between a front and a trailing edge of the upper surface, wherein the frontal structure further includes a ramp surface extending at an angle between the upper cladding and the front edge of the upper surface, the ramp surface pointing upwards and forwards. [12] Dashboard according to claim 11, wherein: the airbag module is configured to deploy the airbag upwards and backwards, causing the airbag to move upwards and backwards over the ramp surface and the upper surface of the frontal structure. [13] Dashboard according to claim 11 or 12, wherein: the upper surface of the frontal structure has a convex curvature and the rear edge of the upper surface of the frontal structure is lower than the first edge of the upper surface of the frontal structure. [14] Vehicle, comprising: a body comprising a passenger compartment with a front driver's side compartment and a front passenger side compartment; a dashboard main substrate that is attached to the body and positioned in front of the front driver's side space and in front of the front passenger's side space; a support substrate attached to a top surface of the main dashboard substrate, wherein the support substrate has a front edge, a rear edge and a central section between the front and rear edges, the central section comprising a driver's side and a passenger's side; an airbag flap assembly comprising a base structure attached to the mounting substrate on the passenger side thereof, wherein the airbag flap assembly includes at least one flap connected to the base structure by a hinge; and wherein the support substrate includes a predetermined breaking point located under the flap of the airbag flap assembly; an upper panel extending over the central section of the mounting substrate and the airbag flap assembly; Foam that is positioned between the mounting substrate and the upper trim panel and between the airbag flap assembly and the upper trim panel; and an airbag module positioned below the shear strip, whereby an airbag of the airbag module tears the shear strip and the foam above the airbag flap assembly when the airbag module deploys, causing the at least one flap to pivot upwards around the hinge, thereby tearing the upper trim to allow the airbag to expand and deploy above the upper trim. [15] Vehicle according to claim 14, comprising: a front structure extending along the rear edge of the support substrate, wherein the front structure includes an upwardly pointing upper surface extending between a front and a rear edge of the upper surface, wherein the front structure further includes a forward and upwardly pointing angled step surface extending between the upper cladding and the front edge of the upper surface.

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