Patent Description:
Generally, air bag devices are installed in vehicles for safety of passengers, and among air bag devices, a passenger air bag (PAB) is a device for protecting a passenger sitting in the front passenger seat.

A PAB is installed in a crash pad and has a structure that deploys through an air bag door of a PAB chute in the case of a vehicle crash. As the deployment structure, the air bag door is opened along a designated cutting line of the crash pad and allows the air bag to deploy.

<CIT> relates to an air bag door. <CIT> relates to a door panel structure that has a pre-weakened hinge and tearable seams formed for air bag deployment. <CIT> relates to an airbag cover. <CIT> relates to an airbag door integrated type crash pad. <CIT> relates to an airbag door connecting structure of a passenger seat of a vehicle.

In one general aspect, here is provided a passenger air bag (PAB) device that includes a crash pad and a PAB chute. The crash pad includes a cutting groove recessed at a predetermined depth in an inner side surface of the crash pad. The PAB chute includes an air bag door welded to the inner side surface in a shape covering the cutting groove. The air bag door includes a protruding portion protruding from a surface of the airbag door, disposed, in a state in which the air bag door is welded to the inner side surface, inside a space forming the cutting groove.

The cutting groove includes an inclined surface reflecting a draft angle, and a flat surface facing the inclined surface and not reflecting the draft angle. The cutting groove extends in a width direction of a vehicle and constitutes a cutting line configured to be cut open by the air bag door, and the space is provided between the inclined surface and the flat surface.

The protruding portion may include a first surface extending upward from the surface, disposed parallel to the inclined surface, and a second surface extending downward from an end of the first surface toward the surface, disposed parallel to the flat surface. The protruding portion has a triangular cross-sectional structure having the first surface as a hypotenuse.

The protruding portion may further include an auxiliary protruding portion protruding outward from the second surface.

The protruding portion may be formed of one of a single split member and a plurality of split members, and may be arranged in a shape extending along the cutting groove.

The plurality of split members may be formed in different sizes.

The crash pad may include a panel portion in which the cutting groove is formed and a skin portion configured to cover an upper surface of the panel portion.

A portion of the skin portion that is exposed toward the cutting groove between the inclined surface and the flat surface may constitute the cutting line.

The air bag door may include a pair of door portions disposed in an opening formed in the PAB chute and a hinge portion configured to rotatably connect the pair of door portions to the PAB chute.

The protruding portion may be provided in an area of the door portion disposed below the inclined surface among the pair of door portions that vertically overlaps the inclined surface.

The door portion may include a welding rib protruding from a surface of the door portion, and a protruding length of the protruding portion may be larger than a protruding length of the welding rib.

The door portion may be partially connected to the PAB chute through a connecting rib extending from a side surface of the door portion in a short side direction of the door portion.

The PAB device may further include an air bag mounted on the PAB chute.

Advantages and features of the present disclosure and methods of achieving the advantages and features will be clear with reference to embodiments described in detail below together with the accompanying drawings. However, the present disclosure is not limited to the embodiments disclosed herein but will be implemented in various forms. The embodiments of the present disclosure are provided so that the present disclosure is completely disclosed, and a person with ordinary skill in the art can fully understand the scope of the present disclosure. The present disclosure will be defined only by the scope of the appended claims. Meanwhile, the terms used in the present specification are for explaining the embodiments, not for limiting the present disclosure.

Spatially relative terms such as "above," "upper," "below," and "lower" may be used herein for ease of description to describe one element's relationship to another element as shown in the figures. Such spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, an element described as being "above" or "upper" relative to another element will then be "below" or "lower" relative to the other element. Thus, the term "above" encompasses both the above and below orientations depending on the spatial orientation of the device. The device may also be oriented in other ways (for example, rotated <NUM> degrees or at other orientations), and the spatially relative terms used herein are to be interpreted accordingly.

Due to manufacturing techniques and/or tolerances, variations of the shapes shown in the drawings may occur. Thus, the examples described herein are not limited to the specific shapes shown in the drawings, but include changes in shape that occur during manufacturing.

<FIG> is a view schematically illustrating a configuration of a passenger air bag (PAB) device according to an embodiment of the present disclosure, <FIG> is a view schematically illustrating a cross-section of the PAB device according to an embodiment of the present disclosure, <FIG> is a view schematically illustrating an inner side surface of a crash pad in the PAB device, and <FIG> is a view schematically illustrating a cross-section of a portion of the crash pad of <FIG> where a cutting groove is formed.

Referring to the drawings, the PAB device <NUM> according to an embodiment of the present disclosure includes a crash pad <NUM>, a PAB chute <NUM>, and an air bag <NUM>.

The crash pad <NUM> may have a cutting line <NUM> positioned at the front passenger seat of a vehicle. The cutting line <NUM> is cut open by an air bag door <NUM> upon the inflation of the air bag <NUM> that is caused by a crash of the vehicle. In this way, the cutting line <NUM> allows the air bag <NUM> to deploy.

The crash pad <NUM> includes a cutting groove <NUM> formed to be recessed at a predetermined depth in an inner side surface thereof, and the cutting groove <NUM> may extend in a width direction of the vehicle and constitute the cutting line <NUM>.

As in the drawings, the crash pad <NUM> may include a panel portion <NUM> in which the cutting groove <NUM> is formed and a skin portion <NUM> configured to cover an upper surface of the panel portion <NUM>.

The panel portion <NUM> corresponds to a lower layer of the crash pad <NUM> and may be formed by injection molding. In an embodiment, the panel portion <NUM> may be made of a paint protection film (PPF) material.

The cutting groove <NUM> is formed along with the panel portion <NUM> during injection molding of the panel portion <NUM> due to a shape processed in a mold for injection molding of the panel portion <NUM> and may be formed by so-called "in-mold scoring.

Accordingly, the cutting groove <NUM> has a structure including an inclined surface <NUM> reflecting a draft angle and a flat surface <NUM> which faces the inclined surface <NUM> and does not reflect the draft angle. Also, a space (for example, an empty space) S forming the cutting groove <NUM> may form a triangular cross-sectional structure having the inclined surface <NUM> as a hypotenuse between the inclined surface <NUM> and the flat surface <NUM>.

The inclined surface <NUM> and the flat surface <NUM> may each be formed to have a structure extending from a lower surface of the panel portion <NUM> to an upper surface thereof, and the cutting groove <NUM> may be formed to pass through the panel portion <NUM> due to a thickness of the mold.

Such a structure of the cutting groove <NUM> corresponds to a feature due to the application of in-mold scoring, and the structure may be formed to have a substantially triangular cross-section due to a draft angle for ejection from the mold.

Of course, according to embodiments, a method of forming the cutting groove <NUM> by postprocessing through milling, laser, or the like after injection molding of the panel portion <NUM> may also be considered. However, since there is a problem of an increase in manufacturing costs in this case, forming the cutting groove <NUM> by in-mold scoring in order to reduce costs is described in the present embodiment.

The cutting groove <NUM> formed in this way may longitudinally extend in the width direction of the vehicle and constitute the cutting line <NUM>.

In an embodiment, reinforcing ribs <NUM> may be provided at predetermined intervals in the cutting groove <NUM> in a longitudinal direction thereof. The reinforcing ribs <NUM> prevent distortion of the panel portion <NUM> due to the formation of the cutting groove <NUM> and may be formed during injection molding of the panel portion <NUM>.

A breakage groove <NUM> and a hinge groove <NUM> may be formed at a periphery of the cutting groove <NUM>.

The skin portion <NUM> corresponds to an upper layer of the crash pad <NUM>. The skin portion <NUM> may cover the upper surface of the panel portion <NUM> and be exposed inside the vehicle.

A portion of the skin portion <NUM> that is exposed toward the cutting groove <NUM> between the inclined surface <NUM> and the flat surface <NUM> may constitute the cutting line <NUM>.

The skin portion <NUM> may be formed by injection molding. The panel portion <NUM> may be inserted, and the skin portion <NUM> may be integrally injection molded with the panel portion <NUM>. In an embodiment, the skin portion <NUM> may be made of a thermoplastic polyurethane (TPU) material.

<FIG> schematically illustrate the PAB chute <NUM> and the air bag door <NUM> according to an embodiment of the present disclosure.

Referring to the drawings, the PAB chute <NUM> may include a main body portion <NUM> and a sidewall portion <NUM>.

The main body portion <NUM> may be provided in a substantially plate-like shape and may be coupled to the inner side surface of the crash pad <NUM> by welding. In an embodiment, the main body portion <NUM> may include a welding rib 21a and be coupled by methods such as vibration welding.

An opening H formed to pass through a central area may be provided in the main body portion <NUM>.

The sidewall portion <NUM> may be provided to extend to a lower portion of the main body portion <NUM> and may have an accommodation space configured to accommodate the air bag <NUM> therein.

The air bag <NUM> may be mounted in the sidewall portion <NUM>. The air bag <NUM> may be made of a fabric material having flexibility and may be configured to inflate due to a gas generated from an inflator (not illustrated).

The PAB chute <NUM> has the air bag door <NUM> welded to the inner side surface of the crash pad <NUM> in a shape that covers the cutting groove <NUM>.

The air bag door <NUM> may be disposed in the opening H of the main body portion <NUM>.

The air bag door <NUM> includes a protruding portion <NUM> protruding from a surface thereof. Also, the air bag door <NUM> is configured so that, in a state in which the air bag door <NUM> is welded to the inner side surface of the crash pad <NUM>, the protruding portion <NUM> is disposed inside the empty space S forming the cutting groove <NUM>.

That is, the cutting line <NUM> of the crash pad <NUM> is a portion whose thickness is weakened due to the formation of the cutting groove <NUM> and thus may easily break. Also, due to a decrease in flexural rigidity, sinking may occur in the empty space S forming the cutting groove <NUM>. Thus, the protruding portion <NUM> is formed on the surface of the air bag door <NUM> to fill the empty space S forming the cutting groove <NUM>, and in this way, the crash pad <NUM> is supported so as not to sink where the cutting line <NUM> is formed, and rigidity may be improved so that the cutting line <NUM> does not easily break.

In an embodiment, the air bag door <NUM> may be made of a thermoplastic olefin (TPO) material.

The air bag door <NUM> may include a pair of door portions <NUM> disposed in the opening H formed in the PAB chute <NUM> and a hinge portion <NUM> configured to rotatably connect the pair of door portions <NUM> to the PAB chute <NUM>.

The door portions <NUM> may open or close the opening H in a split structure. The door portions <NUM> may be configured to open toward each of the interior and an engine room.

The hinge portion <NUM> may connect a side surface of each door portion <NUM> in a long side direction thereof to the main body portion <NUM> of the PAB chute <NUM>. The hinge portion <NUM> may have a substantially V-shaped or U-shaped cross-sectional structure.

Also, the door portion <NUM> may be partially connected to the main body portion <NUM> of the PAB chute <NUM> through a connecting rib <NUM> extending across the opening H from a side surface of the door portion <NUM> in a short side direction thereof. The connecting rib <NUM> may be formed to have a small thickness to break upon opening of the door portion <NUM>.

The door portion <NUM> may include a welding rib <NUM> formed to protrude from a surface thereof. Also, the protruding portion <NUM> may be provided on the surface of the door portion <NUM> parallel to the welding rib <NUM>.

A protruding length of the protruding portion <NUM> may be relatively larger than a protruding length of the welding rib <NUM>.

The protruding portion <NUM> may be provided in an area of the door portion <NUM> disposed below the inclined surface <NUM> of the cutting groove <NUM> among the pair of door portions <NUM> that vertically overlaps the inclined surface <NUM>.

As in the drawings, the protruding portion <NUM> may include a first surface <NUM> which extends upward from the surface and is disposed parallel to the inclined surface <NUM> of the cutting groove <NUM> and a second surface <NUM> which extends downward from an end of the first surface <NUM> toward the surface and is disposed parallel to the flat surface <NUM> of the cutting groove <NUM>.

The protruding portion <NUM> may have a triangular cross-sectional structure having the first surface <NUM> as a hypotenuse. That is, the protruding portion <NUM> may have a shape that corresponds to the cross-sectional shape of the empty space S forming the cutting groove <NUM>.

The protruding portion <NUM> is disposed in the empty space S of the cutting groove <NUM> in a state in which the protruding portion <NUM> is welded to the inner side surface of the crash pad <NUM> through the welding rib <NUM>. In this way, a vulnerable structure of the crash pad <NUM> can be compensated for.

Also, in a process in which the air bag <NUM> inflates and the door portions <NUM> open, the protruding portion <NUM> provides support by coming in direct contact with the inclined surface <NUM> of the cutting groove <NUM>. In this way, an inflation force of the air bag <NUM> is fully applied to the cutting line <NUM> and allows breakage to occur along the cutting line <NUM>.

That is, in a structure without the protruding portion <NUM> as in <FIG>, upon opening of the door portions <NUM> receiving the inflation force of the air bag <NUM>, due to a force F1 applied to the crash pad <NUM> by the door portions <NUM> and a force F2 of the skin portion <NUM> lasting until the skin portion <NUM> is cut open, a crack C starts along the inclined surface <NUM>, and irregular breakage deviating from an intended scoring line occurs.

As a result, a sharp cross-sectional shape is formed along the cut-open cross-section, and this may cause separated fragments to scatter and the deployed air bag <NUM> to be caught. In particular, in a low-temperature environment, the cutting line <NUM> deviates from a set scoring line, and the shape of the cutting line <NUM> becomes irregular and unstable. This may cause damage to the air bag <NUM> and incorrect deployment of the air bag <NUM>, which may cause an injury to a passenger.

Referring to <FIG>, in the structure in which the protruding portion <NUM> fills the empty space of the cutting groove <NUM>, since the protruding portion <NUM> supports the inclined surface <NUM>, a crack C starts along the cutting line <NUM>, and breakage occurs in a regular shape along an intended scoring line. As a result, the uniform cutting line <NUM> may be maintained, and a risk of causing damage to the air bag <NUM> is significantly reduced, which may contribute to quality improvement.

In an embodiment, the protruding portion <NUM> may be formed of a plurality of split members 230a and may be arranged in a shape that extends along the cutting groove <NUM>. The reinforcing ribs <NUM> of the cutting groove <NUM> may be positioned in spaces between the split members 230a. That is, when the protruding portion <NUM> is disposed in the cutting groove <NUM>, in order to prevent interference with the reinforcing ribs <NUM> of the cutting groove <NUM>, the split members 230a may be separated from each other at the positions of the reinforcing ribs <NUM>.

The plurality of split members 230a may be formed in different sizes. For example, the size of the split member 230a disposed at a central area of the door portions <NUM> may be configured to be larger than the size of the split member 230a disposed at both side edge areas of the door portions <NUM>. Such a configuration has an effect of allowing an inflation force of the air bag <NUM>, which is applied to the cutting line <NUM> in the crash pad <NUM>, to be applied more to a central area of the cutting line <NUM> than to edge areas of the cutting line <NUM>.

Of course, the protruding portion <NUM> may be formed of a single structure.

<FIG> schematically illustrates a modified example of the protruding portion <NUM>.

Referring to the drawing, the protruding portion <NUM> may further include an auxiliary protruding portion <NUM> protruding outward from the second surface <NUM>.

The auxiliary protruding portion <NUM> may extend from the protruding portion <NUM> toward the flat surface <NUM> of the cutting groove <NUM> and may be configured to, upon opening of the door portions <NUM>, press the skin portion <NUM> constituting the cutting line <NUM>.

Accordingly, the auxiliary protruding portion <NUM> may allow an inflation force of the air bag <NUM> to be more directly applied to the cutting line <NUM> so that breakage occurs along the cutting line <NUM> as intended.

An embodiment of the present invention can provide a PAB device allowing breakage to occur along a cutting line of a crash pad upon opening of an air bag door due to the inflation of an air bag, thus preventing a problem that fragments scatter or an air bag is caught and damaged.

Claim 1:
A passenger air bag PAB device comprising:
a crash pad (<NUM>) including a cutting groove (<NUM>) recessed at a predetermined depth in an inner side surface of the crash pad (<NUM>); and
a PAB chute (<NUM>) including an air bag door (<NUM>) welded to said inner side surface in a shape covering the cutting groove (<NUM>),
wherein the air bag door (<NUM>) includes a protruding portion (<NUM>), protruding from a surface of the airbag door (<NUM>), disposed, in a state in which the air bag door (<NUM>) is welded to said inner side surface, inside a space (S) forming the cutting groove (<NUM>) to fill the space (S) to support the crash pad (<NUM>),
wherein the cutting groove (<NUM>) comprises:
an inclined surface (<NUM>) reflecting a draft angle; and
a flat surface (<NUM>) facing the inclined surface (<NUM>) and not reflecting the draft angle, and
wherein the cutting groove (<NUM>) extends in a width direction of a vehicle and constitutes a cutting line (<NUM>) configured to be cut open by the air bag door, and the space (S) is provided between the inclined surface (<NUM>) and the flat surface (<NUM>).