U.S. patent application number 12/845807 was filed with the patent office on 2010-11-18 for air bag deployment chute and method.
This patent application is currently assigned to AUTOMOTIVE COMPONENTS HOLDINGS, LLC. Invention is credited to Kenneth J. Kwasnik, Nicholas A. Mazzocchi, Brian C. Slane.
Application Number | 20100287777 12/845807 |
Document ID | / |
Family ID | 42130455 |
Filed Date | 2010-11-18 |
United States Patent
Application |
20100287777 |
Kind Code |
A1 |
Mazzocchi; Nicholas A. ; et
al. |
November 18, 2010 |
Air Bag Deployment Chute and Method
Abstract
An integrated air bag support structure that includes a support
base for attachment to the rear side of a substrate. The support
base is configured to surround a door support panel and both are
configured for attachment to the rear side of a substrate in an
area that is pre-weakened to define an air bag deployment door in a
vehicle instrument panel or a steering wheel air bag module. The
upper surfaces of the support base and door support panel are
attached to the rear surface of the substrate, and a test tab
extends from the base that is attached to the rear surface of the
substrate in the same manner as the support base and the door
support panel. The test tab has an unattached extension portion for
the purpose of gripping and pulling to test the integrity of the
attachment without affecting the attachment of the support
panel.
Inventors: |
Mazzocchi; Nicholas A.;
(Canton, MI) ; Kwasnik; Kenneth J.; (Shelby
Township, MI) ; Slane; Brian C.; (Flatrock,
MI) |
Correspondence
Address: |
AUTOMOTIVE COMPONENTS HOLDINGS LLC;C/O MACMILLAN, SOBANSKI & TODD, LLC
ONE MARITIME PLAZA, FIFTH FLOOR, 720 WATER STREET
TOLEDO
OH
43604-1853
US
|
Assignee: |
AUTOMOTIVE COMPONENTS HOLDINGS,
LLC
Dearborn
MI
|
Family ID: |
42130455 |
Appl. No.: |
12/845807 |
Filed: |
July 29, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12264304 |
Nov 4, 2008 |
7784820 |
|
|
12845807 |
|
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|
|
Current U.S.
Class: |
29/897.2 ;
29/428 |
Current CPC
Class: |
B29C 66/1122 20130101;
B29C 66/61 20130101; Y10T 29/49826 20150115; Y10T 29/4998 20150115;
B29C 65/06 20130101; B29C 66/112 20130101; B29C 66/532 20130101;
B60R 21/215 20130101; B60R 21/217 20130101; B29C 66/54 20130101;
B29C 66/114 20130101; B60R 2021/2163 20130101; B29C 66/30223
20130101; Y10T 29/49622 20150115; B29C 66/131 20130101; B29L
2031/3038 20130101 |
Class at
Publication: |
29/897.2 ;
29/428 |
International
Class: |
B21D 53/88 20060101
B21D053/88; B23P 11/00 20060101 B23P011/00 |
Claims
1. A method of assembling an air bag deployment system of an
automotive vehicle, comprising the steps of: providing an air bag
deployment structure that includes a support base for attachment to
the rear surface of an occupant facing substrate; providing said
support base with upper and lower surfaces configured to surround a
defined air bag deployment door in said substrate, said upper
surface of said support base being configured to be substantially
continuously attached to said rear surface of said substrate;
providing a test tab having a first portion adjacent to and
extending from said support base and a second gripping portion
extending outward from said first portion, wherein said first
portion is also attached to said rear surface of said substrate
along with said upper surface of said support base, and wherein
said second portion is not attached to said substrate; providing an
air bag chute extending downward from said support base and
containing a plurality of skirt walls for surrounding an air bag
container and defining the path for deployment of the air bag from
beneath said substrate; and reinforcing at least one of said skirt
walls to form and maintain a rectangular shaped opening for
receiving said air bag container.
2. The method of claim 1 wherein said support base and said test
tab are attached to said substrate by a vibration welding
process.
3. The method of claim 1 wherein said step of reinforcing said
skirt walls includes the step of integrally forming a pair of
strengthening bars external to said skirt walls.
4. The method of claim 3 wherein said step of integrally forming a
pair of strengthening bars includes the step of molding said
support base, said chute, and strengthening bars of TPO
material.
5. The method of claim 1 wherein said step of providing said air
bag chute includes providing said chute with a plurality of windows
spaced along at least one skirt wall to accept and retain hooks
extending from said air bag container during assembly.
6. The method of claim 5 wherein said step of reinforcing said at
least one of said skirt walls includes the step of providing a
strengthening bar between said windows and said chute opening to
extend continuously below said windows to prevent said hooks from
becoming separated from said skirt wall during air bag
deployment.
7. The method of claim 6 wherein said step of reinforcing said at
least one of said skirt walls includes the step of reinforcing
opposing skirt walls.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of copending U.S. application
Ser. No. 12/264,304, filed Nov. 4, 2008, entitled "Air Bag
Deployment Chute."
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the field of air bag deployment
systems for an automotive vehicle and more particularly to the area
of an air bag chute structure.
[0004] 2. Description of the Related Art
[0005] In this technology field, there have been several attempts
to provide a passenger air bag chute integrated with a hinged
deployment door and a support structure for underlying a vehicle
interior panel.
[0006] U.S. Pat. No. 6,467,801 describes an air bag deployment
chute with a hinge member that is attached between the door and a
base reinforcement portion that surrounds the door.
[0007] U.S. Pat. No. 7,178,825 describes several embodiments of an
air bag deployment chute. Several embodiments show an integral
structure that contain windows for interconnecting with hooks
extending from an air bag container. Other embodiments show add-on
reinforcements to the windows.
[0008] U.S. Pat. No. 7,275,759 shows a multi-piece air bag chute
with side windows that are formed to collapse during air bag
deployment and allow portions of the chute and outer cover to move
outwards from the container during air bag deployment.
BRIEF SUMMARY OF THE INVENTION
[0009] The inventive concept is directed to an improved method and
apparatus, for use in an air bag deployment system, that includes
an air bag deployment structure and chute formed to have
reinforcing members to maintain a rectangular chute opening during
air bag installation and to prevent separation of the chute from
the air bag container due to tear-through of windows during air bag
deployment.
[0010] The inventive concept includes an integrated structure with
a support base for attachment to the rear side of a vehicle
interior substrate. The support base is configured to surround a
door support panel for attachment to the rear side of the substrate
in an area that is pre-weakened to define an air bag deployment
door in a vehicle instrument panel or a steering wheel air bag
module. A rectangular air bag chute tube extends downward from the
support base and contains a plurality of skirt walls for
surrounding an air bag container and to define the path for
deployment of the air bag from the air bag container. The door
support panel is generally co-planar with the support base when
attached to the substrate, but is separated from the support base
by a gap on all four sides. A hinge element extends between one of
the skirt walls of the air bag chute tube and one edge of the door
support panel, and includes a pair of pivoting elements and an arm
extension. The skirt walls of the chute form a rectangular opening
opposite the door support panel for accepting insertion of the air
bag container during assembly. Windows are provided in at least one
skirt side wall of the chute for receiving hooks that extend from
the air bag container. In addition, strengthening bars are formed
beneath the windows and adjacent the chute opening. The
strengthening bars function to maintain the rectangular shape of
the chute opening during assembly with the air bag container and to
subsequently prevent contact between the larger chute and the
smaller air bag container that would otherwise cause noise during
vehicle operation, due to vibrational contact. The strengthening
bars also prevent the chute from becoming detached from the air bag
container hooks by providing added mass to the skirt wall below the
windows.
[0011] Therefore, it is an object of the inventive concept to
provide an improved energy management method and system for an air
bag deployment system that reduces the energy present on the door
member during air bag deployment and the resultant forces which may
otherwise cause separation of the air bag chute from the air bag
container.
[0012] It is another object of the inventive concept to provide an
improved air bag chute that is integrated in structure with
reinforcement bars below the skirt wall windows.
[0013] It is a further object of the inventive concept to provide a
method of making an integrated structure that embodies the claimed
features.
[0014] A more complete description of an embodiment of the
inventive concept is presented below.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a vehicle instrument panel
illustrating air bag deployment areas in which the present
inventive concept may be employed.
[0016] FIG. 2 is a cross-sectional plan view taken along section
line 2-2 in FIG. 1, which shows an embodiment of the inventive
concept connected to a substrate and an air bag container
assembly.
[0017] FIG. 3 is a top plan view of an embodiment of the inventive
concept prior to installation in a vehicle air bag deployment
system.
[0018] FIG. 4 is a cross-sectional perspective view taken along
section line 4-4 in FIG. 3
[0019] FIG. 5 is a perspective bottom view of the embodiment shown
in FIGS. 3 and 4.
[0020] FIG. 6 is another perspective bottom view of the embodiment
shown in FIGS. 3-5.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 represents a typical vehicle instrument panel 10 into
which the inventive concept may be installed. Additionally, the
inventive concept is suitable for inclusion in a steering wheel air
bag module 20.
[0022] In FIGS. 2, 3 and 4, the support base 101 of air bag
deployment structure 100 is shown to have upper and lower surfaces.
The upper surface of support base 101 contains a plurality of
welding ribs 118 to facilitate attachment to the lower surface 11
of substrate 14 with a vibration welding process. (Of course other
types of attachment such as ultrasonic welding, adhesives and other
commonly known techniques may be acceptable substitutes, provided
they preserve the energy absorbing characteristics described
herein.) A door support panel 104, containing welding ribs 119, is
also attached to the lower surface 11 of substrate 14, but within
an area defined as the air bag deployment door by the pre-weakened
seams 12 and 13. In this configuration, the door tear seam 12 is
pre-weakened to the extent that the outer surface of instrument
panel 10 and the substrate 14 will completely rupture upon
deployment of the air bag. Seam 13 is a hinge seam and is formed to
provide a pivot point for the substrate and outer skin of the
instrument panel 10. Therefore it may be pre-weakened to a lesser
extent than door seam 12.
[0023] The air bag deployment structure 100 is formed as a one
piece molding of a flexible material such as Dexflex.RTM. by Solvay
Engineered Polymers, (a "thermoplastic olefinic elastomer (TPO)"),
or other material that exhibits equivalent or superior ductility at
very cold temperatures at least to -30.degree. C. and good
toughness at high temperatures at least to 90.degree. C. Other
materials such as TPO (Thermoplastic Olefin), TPE (Thermoplastic
Elastomer or TEO (Thermoplastic Elastomer Olefin) could be
substituted. It is believed that various pieces could be separately
formed and joined together to replicate the one piece molded
embodiment. If that is done, care will have to be made in order to
obtain the energy management that is offered by the integration of
the various elements that make up the disclosed structure.
[0024] Support base 101 is a generally planar flange that is
substantially coplanar with the door support panel 104. As shown in
the figures, there is a slight curvature that is intended to
correspond to the substrate surface to which the structure
attaches. Such a substrate could be curved or perfectly flat. For
purposes of this discussion, the support base 101 and the door
support panel 104 are described as generally planar to mean that
they are configured to be attached to the underside of the
substrate 12 that is generally smooth and continuous.
[0025] In the depicted embodiment, an alignment slot 137 is
provided in an extension from support base 101. Although not shown,
the substrate 12 may have a protrusion formed therein and extending
from its lower surface to provide a keying feature that assists in
the correct placement of the support structure 100 prior to being
welded to the substrate. Apertured tabs 131, 133 and 135, extending
from support base 101, are used to accept other protrusions
extending from the lower surface of substrate 12.
[0026] A test tab extension 139 is shown as having deformable ribs
138 that are identical in content to deformable ribs 118 and 119
for attachment to the corresponding lower surface area of the
substrate 12 during the same vibration welding process. The test
tab extension 139 allows the welding vendor, the assembler, or
subsequent customer to grip the unattached extension portion 136
while performing quality control testing by applying a pull
pressure to the tab and thereby ensure that the entire weld of the
support structure 100 to the substrate is of the same quality.
[0027] Door support panel 104 and support base 101 are separated by
a gap 112 so that door support panel 104 is not directly attached
to the support base 101. The support base 101 extends under the
pre-weakened door seams 12 and 13 and therefore provides resistance
to inward pressures that may be applied to the outer surface of the
instrument panel 10. In the depicted embodiment, several apertures
110 are shown in door support panel 104. Apertures 110 are
positioned to reduce the mass of the door support panel 104 without
affecting its support or attachment properties.
[0028] An air bag chute tube is formed by skirt walls 105,106, 107
and 108 which extend downward from support base 101. In this
embodiment, the air bag chute tube has a rectangular configuration
defined by end skirt walls 105 and 107, and side skirt walls 106
and 108. Angle gussets 128 and 129 are spaced along the outside of
the skirt side and end walls to provide added strength and some
rigidity between the support base 101 and the air bag chute
tube.
[0029] A hinge element 200 extends between the side skirt wall 108
and hinge edge 107 of door support panel 104. Hinge element 200
includes respective first and second pivoting elements "A" and "B"
and an arm extension 103. From the end, it can be seen that the
first pivoting element A is formed with a downwardly directed curve
having one end connected to the inner side of side skirt wall 108
and the other end connected to said second pivot element B. The
second pivot element B is formed with an upwardly directed curve
having one end connected to the first pivot element A and the other
end connected to extension arm 103. Extension arm 103 extends
upwards from second pivot element B to a hinge edge 107 of said
door support panel 104. Each pivot element is an axial extension
substantially parallel to each other and to the edge of the door
panel to which the arm extension 103 is connected. Each pivot
element, as well as arm extension 103, extends approximately the
full length of the hinge edge 107.
[0030] The longer side skirt walls 108 contain several window
apertures 114 and 116 for engagement with a corresponding number of
attachment hooks extending from an air bag container (not shown).
Window apertures 114 and 116 have pressure tabs 115 and 117 that
bear against the inserted hooks to tighten the engagement
connections and prevent rattling from occurring between the air bag
container and the air bag chute during vehicle operation, prior to
air bag deployment.
[0031] The lower portions of the side skirt walls 108, below the
windows 114 and 116, contain reinforcement bars 122 and 124.
Reinforcement bars 122 and 124, in the depicted embodiment, are
formed on the edge of the chute opening and in effect double the
thickness of the side skirt wall material at the chute opening.
Reinforcement bars 122 and 124 are formed along the entire length
of side skirt walls 108 and function to maintain the sides of the
chute parallel during assembly of the air bag container to the
chute. By maintaining the chute side walls parallel, there is less
opportunity for noise vibration to be generated between the air bag
module and the chute over the life of the undeployed unit.
[0032] The bars also prevent air bag container hooks from
completely tearing through the side skirt walls from their
positions in the windows 114 and 116 when the air bag is deployed.
During air bag deployment, severe pressure is initially present
within the air bag container and chute due to the explosive gases
that are generated. Because the air bag container is fixed to the
structure of the vehicle, the air bag container hooks serve to
prevent separation of the air bag support structure 100 and the
instrument panel from their intended locations during air bag
deployment. The air bag container hooks interact with side skirt
walls 106 and 108 below the windows 114 and 116 to contain the
pressure and allow the chute to remain intact, while the pressure
is directed to the door support panel 104. The directed pressure
forces the tear seams 12 to rupture and the air bag to deploy. Some
prior art applications use metal side walls in air bag chutes to
prevent tearing. In the described embodiment where a thermoplastic
material, such as noted above, is molded to form an integrated
structure 100, the double thickness strengthening bars 122 and 124
combine with the side walls 108 and 106 to prevent the hooks from
completely tearing through the skirt walls and do not allow
separation of the air bag support structure 100.
[0033] It can be seen from the drawings and accompanying
explanation, that the present inventive concept is a unique
improvement over conventional air bag deployment support structures
and methods of managing deployment energy. And while the embodiment
shown here is a preferred embodiment, it shall not be considered to
be a restriction on the scope of the claims set forth below.
* * * * *