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US 6,669,228 B2Granted
Air bag cover of polymeric foam having weakened region
AssigneeDelphi Technologies, Inc.
InventorsSuresh D. Shah, Carl Visconti, Michael W. Jary, William J. Filipp
Life of this patent
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Abstract
A cover for an air bag module is provided. The cover comprises a polymeric sheet and one or more thinned portions. The polymeric sheet has a first surface and a second surface and includes a plurality of cells formed therein. A skin is formed on at least the first surface. The thinned portions are formed in the second surface and define a weakened region of the cover.
Claims30
A cover for an air bag module, comprising:
- a polymeric sheet having a first surface and a second surface, said polymeric sheet including a plurality of cells formed therein, and a skin being formed on at least said first surface;
- and
- one or more thinned portions being formed in said second surface, said one or more thinned portions defining a weakened region of said cover, wherein said plurality of cells comprises a first plurality of cells and a second plurality of cells, said first plurality of cells being defined at said one or more thinned portions and said second plurality of cells being defined in remaining portions of said polymeric sheet, said first plurality of cells reducing a density of said polymeric sheet more than said second plurality of cells.
A cover for an airbag module, comprising:
- a foamed polymeric sheet having a show surface and a non-show surface, and a first skin being formed on at least said show surface;
- and
- a weakened region being formed by one or more thinned portions defined in said non-show surface,
- wherein said foamed polymeric sheet comprises a first zone of cells defined at said weakened region, and a second zone of cells defined in non-weakened regions of said cover, wherein said first zone of cells reduces the density of said weakened region more than said second zone of cells reduces the density of said non-weakened regions.
1 more element
An air bag module, comprising:
- a housing being positionable in a cavity defined in the interior of a vehicle;
- an inflatable cushion;
- an inflator in fluid communication with said inflatable cushion;
- and
- a cover comprising a foamed polymeric member having a show surface, a non-show surface, and a weakened region, said weakened region being defined by one or more thinned portions, said cover being configured such that said non-show surface covers said housing proximate said inflatable cushion whereby inflation of said inflatable cushion by said inflator causes said inflatable cushion to expand into said cover, and thus to apply a force on said cover to tear or open said cover along said weakened region thereby providing an outlet for said inflatable cushion through said cover into said vehicle,
- wherein said plurality of cells further comprises a first zone of cells defined at said weakened region, and a second zone of cells defined in remaining regions of said foamed polymeric member, wherein said first zone of cells reduces the density of said weakened region more than said second zone of cells reduces the density of said remaining region.
3 more elements
A method of making a cover for an air bag module, comprising:
- mixing a blowing agent and a molten polymer under a first condition, said first condition being sufficient to prevent said blowing agent from forming bubbles in said polymer;
- changing said first condition to a second condition, said second condition being sufficient to cause said blowing agent to form bubbles in said molten polymer;
- molding said molten polymer containing said bubbles into a desired shape in a mold, said desired shape comprising a first polymer sheet having a plurality of first cells being defined therein by said bubbles and a thinned portion being defined in a first surface of said first polymer sheet, said mold includes a blade positioned and configured to define said thinned portion;
- and
- cooling said mold to form a first skin on said first surface of said first polymer sheet, said first skin including a first portion defined at said thinned portion and a second portion defined in non-thinned portions of said first polymer sheet, said first portion being thinner than said second portion.
2 more elements
A method of making a cover for an air bag module, comprising:
- mixing a blowing agent and a molten polymer under a first condition, said first condition being sufficient to prevent said blowing agent from forming bubbles in said polymer;
- changing said first condition to a second condition, said second condition being sufficient to cause said blowing agent to form bubbles in said molten polymer;
- molding said molten polymer containing said bubbles into a desired shape in a mold, said desired shape comprising a first polymer sheet having a plurality of first cells being defined therein by said bubbles and a thinned portion being defined in a first surface of said first polymer sheet, said mold includes a blade positioned and confirmed to define said thinned portion;
- and
- expanding said first cells to second cells at said thinned portion by moving said blade from a first position to a second position, said blade being farther from said second surface in said second position than in said first position.
2 more elements
A method of controlling the density of a region of a foamed polymer, comprising:
- mixing a blowing agent and a molten polymer under a first condition, said first condition being sufficient to prevent said blowing agent from forming bubbles in said polymer;
- changing said first condition to a second condition, said second condition being sufficient to cause said blowing agent to form bubbles in said molten polymer;
- molding said molten polymer containing said bubbles into a desired shape in a mold, said desired shape including a plurality of first cells being defined within said desired shape by said bubbles;
- and
- moving a portion of said mold disposed at said region from a first position to a second position, movement of said portion of said mold causing said first cells in said region to change to second cells without changing said first cells in remaining regions of said foamed polymer, said foamed polymer having a first density at said remaining regions caused by said first cells and a second density at said region caused by said second cells.
2 more elements
Dependencies are inferred from the claim text.