Ford Global Technolgoies, LLC

Automotive Components Holdings, LLC

Faurecia Interior Systems, Inc.

Raymond Edward Kalisz

Charles Alan Rocco

Kenneth J Kwasnik

Jeffery N Conley

Nicholas Andrew Mazzocchi

Michael G Orlowsky

Wes Roy

James Steele

Scott Beam

Adrien Bender

Harold P Sears

Ronald H Hasenbusch

James Todd Kloeb

Alan Lawrence Jacobson

Bernie Gerard Marchetti

Larry Edward Ellis

Johnathan Andrew Line

Michael James Whitens

Lisandro Trevino

Roger J Chen

Elizabeth Cleary Johnston Tengler

Rosaria Lee Petrella-Lovasik

Wan-San Chiu

Dana M Niemiec

Interior panels having integrated airbag doors for motor vehicles are provided. In one example, an interior panel comprises a substrate having outer and inner surfaces and an opening extending therethrough. An airbag chute-door assembly is mounted to the substrate and comprises a chute wall that at least partially surrounds an interior space. The chute wall is configured for stowing an airbag module. The chute wall defines an expansion feature that facilitates moving sections of the chute wall for assembling the airbag module to the chute wall. A door flap portion is pivotally connected to the chute wall and at least partially covers the opening. A perimeter flange extends from the chute wall and has a flange section that overlies the outer surface of the substrate. A skin covering extends over the substrate and a foam is disposed between the skin covering and the substrate.

Foam-in-place interior panels having integrated airbag doors including substrates with airbag chute-door assemblies for motor vehicles

Interior panels having integrated airbag doors for motor vehicles are provided. In one example, an interior panel comprises a substrate having an opening. A skin covering and foam cover the substrate. An airbag chute-door assembly is mounted to the substrate. The airbag chute-door assembly comprises a chute wall that at least partially surrounds an interior space. The chute wall is configured to direct passage of an airbag through the interior space towards the opening. A door flap portion is pivotally connected to the chute wall via a hinge section and at least partially covers the opening. A gusset hinge feature extends from the hinge section between and operatively coupled to the door flap portion and the chute wall. A perimeter flange extends from the chute wall away from the interior space and has a flange section that overlies the outer surface of the substrate.

Interior panels having integrated airbag doors for motor vehicles are provided. In one example, an interior panel comprises a substrate having an opening. A skin covering and foam cover the substrate. An airbag chute-door assembly is mounted to the substrate and has a front side that faces towards the skin covering and the foam. The airbag chute-door assembly comprises a chute wall that extends from a side opposite the front side. A door flap portion is pivotally connected to the chute wall via a hinge section and at least partially covers the opening. A perimeter flange extends from the chute wall and overlies the substrate. The airbag chute-door assembly has a groove formed in the front side between the door flap portion and the perimeter flange defining a frangible tear seam.

An active bolster is integrated within a seat for a transportation vehicle by covering an inner inflatable bladder with an outer cushion layer to provide a seating support surface. Seating loads are borne on the support surface from the weight of an occupant by elastic deformation of the bladder. When a vehicle crash event is detected, at least a portion of the bladder is inflated to extend a seat surface to protect the occupant. Size and weight of the seat are reduced as a result of the bladder contributing significantly to the normal cushioning of the seat in everyday usage.

Active bolster deployed from vehicle seat

A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.

Molding tool with conformal portions and method of making the same

An active bolster has an expandable inner wall including a bay having first and second opposing ends and a central bowl. An expandable outer wall overlies the inner wall to provide a main cavity therebetween. An inflator is mounted within the bay having an outlet nozzle with a plurality of outlet passages for radially discharging an inflation gas against the bay and the outer wall in response to inflate the main cavity during a crash. The inner wall of the central bowl includes a plurality of first dispersion ribs substantially parallel with one another and following arcuate paths to provide at least one gas channel with opposite ends emptying from the central bowl into the main cavity. The outer wall includes a plurality of second dispersion ribs oriented to channel inflation gas from the central bowl toward the outer peripheral edges.

Active bolster with gas directing channels

A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Mold core for forming a molding tool

An active bolster for automotive crash protection has front and back walls with their outer peripheral edges sealed together to provide a bladder chamber therebetween. A gas source supplies an expansion gas to inflate the bladder chamber during a crash. The back wall has a pleated section comprising a plurality of generally-parallel rows of generally-circumferential pleats that unfold during inflation. The unfolding of the pleats controls a deployment trajectory of the front wall, and the pleats have an undulating transverse curve length corresponding to a maximum trajectory of the front wall. The pleated section further comprises a plurality of transverse ribs joining adjacent pleats in selected locations to reduced the unfolding during inflation to provide a modified deployment trajectory.

Active bolster with cross-connected pleats

An improved air bag deployment system that protects welds or other bonds that are made between the underside of an instrument panel substrate and the outer flange of an air bag deployment chute. A deflector element is located in the gap between the chute flange and the substrate to prevent the deploying air bag from expanding into the gap and potentially damaging the bond.

Air bag deployment system with deflector rib

An active bolster for an automotive vehicle has base wall for mounting against a rigid structure of the vehicle. A front wall overlies the base wall and forms an interior trim piece of the vehicle. The base wall has a first surface facing the front wall, and the front wall has a second surface facing the base wall. The base wall and front wall are joined around a closed perimeter to form an inflatable bladder with an initial open space between the first and second surfaces. The base wall includes a wide rib projecting from the first surface continuously along the closed perimeter, the wide rib having a minimum radial width along the closed perimeter equal to a first predetermined radial width. The front wall includes a plurality of narrow ribs projecting concentrically from the second surface continuously along the closed perimeter. Each narrow rib is welded to the wide rib, and each narrow rib has a respective radial width at each respective location along the closed perimeter less than half the radial width of the wide rib at the respective location.

Active bolster with hermetic seal

An active bolster for an automotive vehicle has an inflatable bladder formed by a reaction wall for mounting against a rigid structure of the vehicle and an expansion wall overlying the base wall. The base wall and expansion wall are comprised of molded plastic components. At least one of the reaction wall and the expansion wall includes a plurality of tether tabs, each tether tab having a contoured edge defining a movable flap. The contoured edge has first and second ends defining a first hinge axis and a pair of complementary undulations defining a second hinge axis substantially parallel to the first hinge axis. The movable flap has an attachment region joined to the other one of the reaction wall and the expansion wall, and the second hinge axis extends between the attachment region and the first hinge axis.

Active bolster with double-hinged tether tabs

An active bolster for protecting an occupant during a crash event of a motor vehicle includes a back wall and a front wall forming an inflatable bladder. The back wall includes a stationary central mounting section and a pleated section with generally-circumferential pleats that unfold during bladder inflation. The pleats provide a transverse curve length that is radially variable with a greatest transverse curve length toward a first end of the wall and a smallest transverse curve length toward an opposite end of the wall so that expansion of the wall is biased toward the to first end.

Active bolster with unsymmetric pleated inflation

An active bolster for a door of a transportation vehicle comprises a sheet metal door frame with a plurality of brackets. A door cover panel is mounted to the door frame. The cover panel has a bolster aperture, a living hinge disposed around the perimeter of the bolster aperture, and a plurality of mounting bosses. A blow-molded bladder is arranged to fit within the bolster aperture having a front surface substantially co-planar with the cover panel, having a pleated back surface, and having a plurality of side mounting tabs extending laterally from the sides of the bladder. Each side mounting tab is attached to a respective mounting boss and includes a respective tear seam configured to pull away from the respective mounting boss during inflation of the bladder. A plurality of capture pins are insert molded into the back surface. Each pin is captured by a respective bracket.

Blow-molded active side bolster with tear tabs

An active bolster for passenger crash protection in a vehicle comprises a base wall and a front wall, the walls having first and second facing surfaces to form an inflatable bladder with an initial open space between the surfaces. The bladder includes a plurality of tear joints. Each tear joint is comprised of first and second upstanding ribs wherein the first upstanding rib extends from the first surface part way into the open space and extends end-to-end along a first direction. The second upstanding rib extends from the second surface part way into the open space to contact the first upstanding rib and extends end-to-end substantially along a second direction that is substantially transverse to the first direction so that the first and second upstanding ribs contact at an intersection. At each intersection the first and second upstanding ribs comprise a welded joint that is substantially rigid against compression forces and that allows the tear joints to separate under tension during inflation of the bladder.

Active bolster with internal tear joints

An active bolster is provided on an generally-planar interior trim panel. An invisible tear seam in the panel follows a closed path that is spaced away from a peripheral edge of the panel. An inflatable bladder has a rim bonded to the panel along an inward edge of the tear seam. A bowl-shaped reaction frame has a cavity receiving the inflatable bladder and has a rim bonded to the panel along an outward edge of the tear seam, so that the inflatable bladder is contained between the reaction frame and the interior trim panel. Inflation of the inflatable bladder causes the interior trim panel to tear at the tear seam causing the portion of the interior trim panel within the closed path to separate and expand away from the reaction frame into the passenger compartment.

Growing community of inventors

Livonia, MI, United States of America

Raymond Edward Kalisz