Abstract:
A blow molded (HIC) formation with energy buffers provides absorption of vehicle occupant cranial impacts. A generally plastic, forced air, expanded formation defines a cavity, the formation walls being of varied geometric shapes having calculated wall thicknesses, each shape having an energy absorbing and resiliency characteristic. The formation of geometric shapes is positioned depending upon the vehicle stiffness characteristics and the degree of impact absorption required. Geometric shapes employed may consist of sinusoidal waveforms, a gabled design, or either of the preceding with an internal strengthening rib employed to alter formation impact absorbing characteristics. The formation contains an orifice to ensure that vehicle occupant energy is efficiently absorbed during the concurrent events of formation compaction and air expulsion through the orifice. The blow molded formation may be glued or otherwise suitably fastened to an automobile headliner, door panel, pillar, or other location.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a motor vehicle occupant impact absorption device, and more particularly to a blow molded mechanical, polymeric structure for dampening automobile occupant head impact energy within a collapsing section. By achieving a prescribed head impact criterion (HIC) rating, the Blow Molded (HIC) Formation with Energy Buffers permits bodily energy, due to vehicular impact, to be absorbed in a controlled fashion. 
     BACKGROUND 
     Vehicle manufacturers and suppliers alike are constantly striving to improve occupant safety. Part of this initiative is increasing the ability of the vehicle interior to absorb occupant energy during a vehicle impact. More specifically, there is a major initiative on behalf of automobile manufacturers to design new energy absorbing materials and new energy absorbing buffers from existing or new materials to equip the interior of automobiles. 
     Major automobile interior impact energy absorbing devices conventionally include extruded polystyrene, extruded polypropylene, other compressible and collapsible foams, and air-operated supplemental restraint systems (SRS) which utilize supplemental air bags (SAB) to restrain vehicle occupants and absorb occupant energy in the event of vehicular impacts. While current occupant restraining and impact energy absorbing devices have proven to be satisfactory for their applications, it remains desirable to advance the relevant art. 
     SUMMARY OF THE INVENTION 
     In accordance with the teachings of the present invention, a blow molded (HIC) formation with energy buffers for absorbing energy during impact with a vehicle headliner or other interior area of a vehicle is disclosed. 
     In one preferred embodiment, the blow molded (HIC) formation with energy buffers is a single and continuous hollow plastic device defined by a surrounding shell. The surrounding shell is formed by a plurality of geometric figures designed to absorb impact in conjunction with the automotive structural device to which it is attached. The major parts of a blow molded (HIC) formation with energy buffers include a plastic peripheral shell and a plurality of geometric formations which define the peripheral shell. The peripheral shell is formed during a blow molding process and may include a strengthening rib to provide an alternate impact criterion for the particular buffer involved. The peripheral shell can also be formed to provide an integrally formed attachment device as part of the attachment side of the peripheral shell. 
     In another preferred embodiment, the blow molded (HIC) formation with energy buffers is a single and continuous hollow plastic device defined by a surrounding shell. The surrounding shell is formed by a plurality of geometric figures designed to absorb impact in conjunction with the automotive structural device to which it is attached. The geometric profiles in this embodiment are a plurality of hipped or gable shaped buffers comprising a single side of the shell. The opposing side of the shell is generally flat and is the mounting side for this embodiment. 
     In still another preferred embodiment, the blow molded (HIC) formation with energy buffers is a single and continuous hollow plastic device defined by a surrounding shell. The surrounding shell is formed by a plurality of geometric figures designed to absorb impact in conjunction with the automotive structural device to which it is attached. The geometric buffers in this embodiment are a plurality of sinusoidal shaped buffers comprising a single side or each side of the shell. The opposing sides of the shell consist of the sinusoidal buffers aligning as mirror images of each other. 
     In yet another preferred embodiment, a blow molded (HIC) formation with energy buffers includes an integrally molded fastener as part of its peripheral shell. The integrally molded fastener is molded into the generally flat side of the peripheral shell, but in the event the shell does not have a generally flat side, they may be molded into either of the buffer containing sides. 
     In yet another preferred embodiment, a blow molded (HIC) formation with energy buffer includes an external fastener, attached by conventional means, to the outside of the generally flat side of the peripheral shell, but in the event the shell does not have a generally flat side, they may be attached to either of the buffer containing sides. 
     In still yet another preferred embodiment, a blow molded (HIC) formation with energy buffer includes an inlet/outlet orifice. The size of the inlet/outlet orifice depends upon the desired rate of air expulsion required upon the impact of the blow molded (HIC) formation. The controlled exhaustion of air assists in the deceleration of any object impacting the device. Additionally, the orifice is used during the blow molding process as an air inlet. 
     In yet another preferred embodiment, a blow molded (HIC) formation with energy buffer includes a shell of varying wall thickness. The wall thickness is varied depending upon the shell deformation characteristics required which depends upon the specific location of the blow molded (HIC) formation with energy buffers within the automobile. The deformation characteristics are also dependent upon the stiffness of the surrounding automobile structure. 
     In yet another preferred embodiment, a blow molded (HIC) formation with energy buffers includes a shell of varying overall thickness. That is, the overall blow molded (HIC) formation with energy buffers may be constructed to be of a variety of overall thicknesses depending upon the location and space constraints within the vehicle. 
     Further in another preferred embodiment, a blow molded (HIC) formation with energy buffers includes a strength rib integrally molded into the buffer of the peripheral shell. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is an environmental view of an automobile showing in phantom, the interior locations of representative examples of the blow molded (HIC) formation with energy buffers. 
     FIG. 2 is a perspective view of an automobile interior showing in phantom, the locations of representative examples of the blow molded (HIC) formation with energy buffers. 
     FIG. 3 is a top view of an automobile showing the blow molded (HIC) formation with energy buffers installed in an automobile interior headliner. 
     FIG. 4 is a perspective view of an automobile interior B-pillar column showing a blow molded (HIC) formation with energy buffers. 
     FIG. 5 is a perspective view of an automobile interior door panel showing a blow molded (HIC) formation with energy buffers. 
     FIG. 6 is a perspective view of an automobile B-pillar, C-pillar and roof section showing the representative positions of the blow molded (HIC) formation with energy buffers on the automobile interior. 
     FIG. 7 is a perspective view of a representative section of a blow molded (HIC) formation with energy buffers showing buffers on a single side of the formation and also on both sides of the formation. 
     FIG. 8 is a front view of a gabled or hipped buffer utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 9 is a front view of a single sinusoidal buffer utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 10 is a front view of a double sinusoidal buffer utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 11 is a perspective view of a representative section of a blow molded (HIC) formation with energy buffers showing buffers on each buffer having an internal strength rib. 
     FIG. 12 is a perspective view of a gabled or hipped buffer, with strength rib, utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 13 is a perspective view of a single sinusoidal buffer, with strength rib, utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 14 is a perspective view of a double sinusoidal buffer, with strength rib, utilized in the blow molded (HIC) formation with energy buffers. 
     FIG. 15 is a perspective view of a representative blow molded (HIC) formation with energy buffers showing buffers with strength ribs on a single side of the formation, and a plurality of integral attachment devices. 
     FIG. 16 is a front view of a single sinusoidal buffer utilized in the blow molded (HIC) formation with energy buffers, the single buffer showing integral external attachment devices. 
     FIG. 17 is a front view of a single sinusoidal buffer, with strength rib, utilized in the blow molded (HIC) formation with energy buffers, the buffer having a plurality of integral internal attachment devices. 
     FIG. 18 is a front view of a double sinusoidal buffer, with strength rib, utilized in the blow molded (HIC) formation with energy buffers, the buffer having an integral external attachment device. 
     FIG. 19 is a side view of a blow molded (HIC) formation with energy buffers, the buffer having an internal strength rib and showing a representative point of impact upon the buffer. 
     FIG. 20 is a side view of a blow molded (HIC) formation with energy buffers showing the point of impact upon the buffer and the intermediate deformation of the strength rib. 
     FIG. 21 is a side view of a blow molded (HIC) formation with energy buffers showing the point of impact upon the buffer and the advanced deformation of the strength rib. 
     FIG. 22 is a side view of a blow molded (HIC) formation with energy buffers showing a representative thickness of the overall formation. 
     FIG. 23 is a side view of a blow molded (HIC) formation with energy buffers showing a representative thickness of the overall formation. 
     FIG. 24 is a side view of a blow molded (HIC) formation with multiple wall thickness energy buffers adhered to an automobile structure. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of a blow molded (HIC) formation with energy buffers is merely exemplary in nature and is not intended to limit the invention or its application or uses. Moreover, while the present invention is described in detail below generally with respect to an automotive interior application, it will be appreciated by those skilled in the art that the present invention is clearly not limited to only an automotive application, and may be applied to various other types of vehicles where occupant protection is desired, as further discussed herein. 
     Referring to FIG. 1, an automobile  10  is depicted showing, in phantom, a representative example of the various locations of a blow molded (HIC) formation with energy buffers  12 ,  14 ,  16 ,  18 ,  20 ,  22 ,  24  and  26  in accordance with the teachings of the present invention. FIG. 2 shows an automobile  10  showing in phantom, the locations of representative examples of the blow molded (HIC) formation with energy buffers  28 ,  30 ,  32  and  34  generally located in the areas where occupant contact is likely during a vehicular impact. FIG. 3 shows a top view of an automobile  10  headliner area  36  with blow molded (HIC) formation with energy buffers  38  and  40 , shown at automobile front end  46 , and buffers  42  and  44  shown at automobile rear end  48 . FIG. 4 shows a blow molded (HIC) formation with energy buffers  50  located in an automobile B-pillar  52  around the area generally occupied by the adjustable shoulder belt direction loop  54  and the shoulder belt adjustment track area  56 . FIG. 5 shows a blow molded formation with energy buffers  58  located in an automobile door panel  60  and around the area occupied by the door handle  62 . FIG. 6 shows a blow molded (HIC) formation with energy buffers  64 ,  66  and  68  located in a rear area  70  of an automobile  10  of FIG.  1 . 
     FIG. 7 shows a blow molded (HIC) formation with energy buffers  72  featuring multiple buffers  74 ,  76 ,  78 ,  80 ,  82 ,  84 ,  86 ,  88  and  90  which define the peripheral shell of the blow molded (HIC) formation with energy buffers  72 . The peripheral shell with multiple buffers defines the internal cavity that results from the blow molding process. Buffer  94  of FIG. 8, buffer  96  of FIG. 9, and buffer  98  of FIG. 10 are representative of the available buffers of the blow molded formation with energy buffers  72  of FIG.  7 . Buffer  94  of FIG. 8 is termed a gabled, or hipped buffer, buffer  96  of FIG. 9 is known as a sinusoidal buffer, and buffer  98  of FIG. 10 is known as a double sinusoidal buffer. Side  92  of FIG. 7 is generally flat or appropriately curved to accommodate the profile of a vehicle headliner or other automotive structure to securely mount the blow molded formation with energy buffers  72  within the automobile. Additionally, the blow molded (HIC) formation with energy buffers  72  features an orifice  100 . The orifice  100  permits the introduction of air to form the blow molded (HIC) formation with energy buffers  72  and also acts as a governor to regulate the rate of air expulsion during an impact. The larger orifice  100  becomes, the faster the rate of expulsion. Therefore, in addition to varying the specific geometric profiles of the buffers to alter the deformation and energy absorbing characteristics of the blow molded (HIC) formation with energy buffers  72 , the size of orifice  100  may be varied. 
     The blow molded (HIC) formation with energy buffers  72  is also adaptable to fit in areas where vehicle structural members, wiring or other conduit might otherwise interfere with the blow molded formation with energy buffers  72 . To adapt to the noted potential interfering vehicle structures, the blow molded formation with energy buffers  72  is moldable with contoured buffer  80  of FIG.  7 . It should also be noted that while the substantial portion of the blow molded (HIC) formation with energy buffers  72  contains a substantially flat surface  92 , FIG. 10 exemplifies that it is within the scope of the present invention to create a blow molded (HIC) formation with energy buffers  72  having a dual profile buffer  98 . A dual profile buffer  98  is a mirror image of itself about its centerline. FIG. 7 also exemplifies a dual profile buffer  84  and  88 . However, it is also within the scope of the present invention to have a dual profile buffer that is not a mirror image of itself, such as the dual profile buffer  88 . It should also be noted that the blow molded (HIC) formation with energy buffers  72  may accommodate multiple buffers along a single surface or on both surfaces simultaneously, as evidenced with buffers  84  and  88 . 
     FIG. 11 shows a blow molded (HIC) formation with energy buffers  102  featuring multiple buffers along a surface  104 . However, buffers  106 ,  108  and  110  of FIGS. 12,  13  and  14 , respectively, incorporate a strengthening rib  112 ,  114  and  116 , respectively, to bolster the buffer strength in absorbing occupant energy. 
     FIG. 15 shows a blow molded (HIC) formation with energy buffers  118  featuring multiple buffers along a side  120  and an opposite, substantially flat surface  122 . Buffer  124  is representative of the buffers along the side  120  designed to absorb impact, and in addition to having an impact absorbing strength rib  126  within its interior, the entire blow molded formation with energy buffers  118  contains integral attachment devices  128 . 
     Buffer  130  of FIG. 16 shows an attachment device  132  which may be integrally molded into the substantially flat surface  134  of the buffer  130 , or the attachment device  132  may be mechanically or thermally attached to the buffer  130 . Alternatively, a buffer  136  as shown in FIG. 17, may have an attachment device  138  molded into a flat surface  140  or an attachment device  142  may be molded into the buffer tip  144 . A double sinusoidal buffer  146  having a strength rib  148  and an attachment device  150  is represented in FIG.  18 . The attachment device  150  may either be integrally molded into the buffer  146  or mechanically attached. 
     With reference to FIGS. 19 through 21, a representative impact will now be explained to further illustrate the advantages of the blow molded (HIC) formation with energy buffers. FIGS. 19 through 21 show a representative blow molded (HIC) formation with energy buffers  152  exhibiting a representative buffer  154  with strengthening rib  156  undergoing a typical deformation when a force represented by arrow  158 , hereinafter, force  158 , is applied. FIG. 19 shows a buffer  154  with a strengthening rib  156  just before the application of force  158 . FIG. 20 shows the initial application of force  158  and an initial absorption of energy and deformation of buffer  154 . Upon continued application of force  158 , the buffer  154  and strengthening rib  156  begin to deform in the directions represented by arrow  160  and arrow  162 . Additionally, FIG. 20 shows how the force  158  and subsequent deformation of buffer  154  also affect adjacent buffers  164  and  166 . The sinusoidal buffer  154  of FIG. 20 allows creep of the material at the initial impact of buffer  154 . A longer true length of line created by the sine wave buffers  164  and  166 , push into the top of collapsible strengthening rib  156  creating a momentary folding of the strengthening rib and the dissipation of energy as the strengthening rib  156  rolls over onto itself until the strengthening rib  156  reaches its fully collapsed position in FIG.  21 . At this point, buffer  154  and rib  156  reach their maximum deformation due to force  158 . An added feature of the blow molded (HIC) formation with energy buffers is the resiliency of the buffers and their ability to absorb energy for more than a single impact. Because of the designs of the buffers, the buffers inherently have a level of spring-back or resiliency built into them. This is what permits the buffers to be utilized for more than a single impact. Therefore, the deformation process due to impact represented by FIGS. 19 through 21 may be repeated in a matter of seconds for a given impact of a given blow molded (HIC) formation with energy buffers. 
     The blow molded (HIC) formation with energy buffers are particularly adaptive to absorbing energy within an automobile interior because of the options available in varying the physical parameters of the blow molded (HIC) formation with energy buffers. For instance, FIG. 22 shows a blow molded (HIC) formation with energy buffers  168  having an overall formation height of  170  and FIG. 23 shows a blow molded (HIC) formation with energy buffers  172  having a lower overall formation height of  174 . The ability to regulate and mold the blow molded (HIC) formation with energy buffers into a variety of overall heights is a significant advantage when designing energy absorbing materials to fit into an automobile where a variety of space limitations restricts the materials available for use, or at least their simple and efficient adaptation to the space allotted. The ability to form the energy buffers in a variety of wall thicknesses along a continuous piece is also beneficial. 
     The blow molded (HIC) formation with energy buffers are moldable into a variety of specific wall thicknesses along a single molded formation. FIG. 24 exemplifies a section view of a blow molded (HIC) formation with energy buffers  176 , having buffers  178 ,  180  and  182 . Continuing, buffer  178  has a cross-sectional thickness  184 , buffer  180  has a cross-sectional thickness  186 , and buffer  182  has a cross-sectional thickness  188 . Because the blow molded (HIC) formation with energy buffers is able to be molded with a varying wall thickness, a variety of impact absorbing characteristics are achievable with a single molded part. This means that the individual stiffness continuum of particular automotive structural members may be taken into consideration with a single blow molded (HIC) formation with energy buffers. This has the advantage of saving parts, material, labor and time when the blow molded (HIC) formation with energy buffers is installed into an automobile  10  as in FIG.  1 . 
     To elaborate further, because the blow molded (HIC) formation with energy buffers  176  of FIG. 24 has multiple wall thicknesses, the formation will accommodate an interior automotive structure of varying stiffness. This presents the advantage of being able to provide the interior occupants with a consistent level of impact absorption at multiple locations within the vehicle interior since each vehicle has interior mounting structures that vary in stiffness. That is, the stiffer a structure, the less likely it is to absorb impact compared to its less stiff counterpart. Accordingly, each structure&#39;s stiffness varies along its length, and because the structural stiffness varies, the structure is able to absorb impact at different rates along its length. In order to meet changing U.S. Federal standards with respect to HIC, the blow molded (HIC) formation with energy buffers compensates for this variation in vehicle structure stiffness. 
     FIG. 24 shows, in addition to a blow molded (HIC) formation with energy buffers  176 , an automobile structural member  190  of varying thickness, which is directly proportional to stiffness. That is, the thicker the cross section, the stiffer the structure. Therefore, the blow molded (HIC) formation with energy buffers  176  of FIG. 24 is designed to accommodate the automobile structure  190  of varying stiffness. As such, buffer  178  has a cross-sectional thickness  184  associated with it and is designed into the blow molded (HIC) formation with energy buffers  176  above the automobile structure  190  at area  192 . Since the automobile structure  190  is thicker at area  192 , relative to area  196 , the cross-sectional thickness  184  of buffer  178  will also be thicker than the buffer  182  above area  196 . This is because the buffer  178  must be capable of decelerating an impacting object (not shown) before the object strikes the automobile structure  190  at area  192 . Accordingly, the object must strike the automobile structure  190  at area  192  after collapsing the buffer  178  at such a reduced rate as to not negatively affect the HIC measurements of the impacting object. If the impacting object is not decelerated enough before striking the automobile structure  190  at area  192 , it will result in an unacceptable HIC. Likewise, buffer  182  has a cross-sectional thickness  188  that is thinner than cross-sectional thickness  184  of buffer  178  because the automobile structure  190  at area  196  is thinner and hence, has a lower stiffness. With regard to HIC, this means that an impact at buffer  182  that is not stopped, will result in an impact at area  196  of the automobile structure  190  which may result in an acceptable HIC. Because the automobile structure  190  at area  196  is of a stiffness that is capable of providing an acceptable level of deceleration, the lesser cross-sectional thickness  188  of buffer  182  is acceptable when compared to buffer  178 . Buffer  180  is designed with a cross-sectional thickness  186  that is intermediate to that of buffer  178  and buffer  182  because the thickness above area  194  of the automobile structure  190  is intermediate to areas  192  and  196 . 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.