Open core crash pad and process for manufacturing thereof

Patent metadata

Field	Value
Publication number	US-2016159304-A1
Application number	US-201514930263-A
Country	US
Kind code	A1
Filing date	Nov 2, 2015
Priority date	Dec 9, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

An open core crash pad includes a core and a skin abutting the core to include a forming space therebetween. A foaming layer is foam-formed by injecting a foam liquid into the forming space. A foam tape prevents an overflow of the foam liquid. The skin includes a body portion and a distal end which extends from the body portion in parallel with the core. The core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact.

First claim

What is claimed is:

1 . An open core crash pad comprising:
a core; a skin abutting the core to include a forming space therebetween; a foaming layer foam-formed by injecting a foam liquid into the forming space; and a foam tape for preventing an overflow of the foam liquid, wherein the skin comprises: a body portion; and a distal end extending from the body portion in parallel with the core, and wherein the core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact.

2 . The open core crash pad of claim 1 , wherein the protrusion and the foam tape are attached to each other.

3 . The open core crash pad of claim 1 , wherein the protrusion comprises a head which is inclined and has a sharp end.

4 . The open core crash pad of claim 1 , wherein the distal end comprises a weakened section which is recessed from an outer side at which the distal end contacts the protrusion.

5 . The open core crash pad of claim 4 , wherein the distal end is removably attached together with the foam tape.

6 . The open core crash pad of claim 1 , wherein the skin is a polyvinyl chloride (PVC) powder slush.

7 . A method of manufacturing an open core crash pad comprising:
inserting a core into an upper mold and inserting a skin into a lower mold; attaching a foam tape to the core or the skin; injecting a foam liquid into a forming space of the skin; and manufacturing a foaming layer by pressing the upper mold and the lower mold, wherein the skin comprises: a body portion; and a distal end extending from the body portion in parallel with the core, and wherein the core comprises a protrusion formed at an inner side of the foam tape at which the core and the distal end abut contact.

8 . The method of claim 7 , wherein the foam tape is closely attached to the protrusion when the upper mold and the lower mold are pressed.

9 . The method of claim 7 , wherein the protrusion comprises a head which is inclined and has a sharp end.

10 . The method of claim 7 , wherein the distal end comprises a weakened section recessed from an outer side at which the distal end contacts the protrusion, and the distal end is removed together with the foam tape.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Kong Byung Seok

Classifications

• B62D29/00

  Superstructures, {understructures, or sub-units thereof,} characterised by the material thereof {(B62D33/044, B62D33/048 take precedence)} · CPC title

• B29K2995/0091

  Damping, energy absorption · CPC title

• B62D25/14 Primary

  Dashboards as superstructure sub-units (other dashboard aspects B60K) · CPC title

• B60R21/04 Primary

  Padded linings for the vehicle interior {; Energy absorbing structures associated with padded or non-padded linings} · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title