1. Field of the Invention
The present invention relates to a molded energy absorber.
2. Background Art
Use of vehicle pillars, and in particular those that absorb energy upon impact, is well known. Often the energy absorbing capability is found within an interior trim component which is attached to the structural pillar.
An example of this type of energy absorbing device is found in U.S. Pat. No. 5,641,195 issued to Patel et al. on Jun. 24, 1997. Patel discloses an interior trim component for a structural pillar that contains an elaborate network of energy absorbing elements. The trim component is a one-piece molded part that has energy absorbing elements integrally molded on the inside surfaces. These elements include a series of ribs and fingers that deflect on impact, thereby absorbing energy.
Another type of energy absorbing pillar cover is disclosed in U.S. Pat. No. 6,068,320 issued to Miyano on May 30, 2000. This device is also a one-piece molded plastic design, in which energy absorbing ribs are integrally molded on the inside of the pillar cover. When the pillar cover is impacted, it elastically deforms to allow the ribs to buckle.
The energy absorbing ribs of the type found in Patel and Miyano are relatively thin. This means they will deform upon impact to absorb some of the impact energy. However, it also means that if the ribs fracture, only small fracture surfaces are formed. Thus, much of the energy absorption capacity of these devices results from the elastic deformation of the ribs. In addition, the Patel and Miyano devices are specifically designed for use as trim components on structural members such as pillars. Although impact energy absorption at pillars is important, providing other interior components, such as sun visors, with energy absorbers, may increase passenger safety.
Accordingly, it is desirable to provide an improved molded energy absorber that is of relatively uncomplicated geometry, and therefore easy to manufacture, and which overcomes the shortcomings of prior art energy absorbers by utilizing energy absorbing structures specifically designed to fracture upon impact to increase the amount of energy absorbed, and which is applicable to various vehicle interior components.
Therefore, one aspect of the present invention provides an improved molded energy absorber for use in the interior of a vehicle that is easily manufactured, has relatively uncomplicated geometry, and relies on the formation of fracture surfaces to absorb impact energy.
Another aspect of the invention provides an improved molded energy absorber that can be used on various vehicle interior components.
Still another aspect of the present invention provides a molded energy absorber for use in the interior of a vehicle that comprises a first section having an inner surface and an outer surface, and at least one longitudinal edge. Integrally molded onto a surface of the first section is a plurality of telescopically crushable tubular elements that are sufficiently telescopically crushable to absorb impact energy. The energy absorber also includes a second section having an inner surface and an outer surface and at least one longitudinal edge. Disposed along a longitudinal edge of the two sections is a hinge element that forms an axis of rotation for folding the two sections together.
Yet another aspect of the invention provides a molded energy absorber for use in the interior of a vehicle that comprises a first section having an inner surface and an outer surface, and at least one longitudinal edge. A plurality of telescopically crushable, generally cylindrical elements is integrally molded onto a surface of the first section. The generally cylindrical elements include a tubular lower portion and a solid upper portion, characterized by a difference in diameter. The difference in diameter between the upper and lower portions creates a shear line along which a fracture surface forms to absorb impact energy when one of the generally cylindrical elements is crushed. The energy absorber also includes a second section having an inner and an outer surface, and at least one longitudinal edge. A hinge element is disposed along a longitudinal edge of the first and second sections, forming an axis of rotation for folding the first section onto the second section.
A further aspect of the invention provides a vehicle structural pillar having an interior side and an exterior side, wherein the interior side is covered with a molded energy absorber that comprises a first section having an inner surface and an outer surface, and at least one longitudinal edge. A plurality of telescopically crushable tubular elements sufficiently telescopically crushable to absorb impact energy is integrally molded onto a surface of the first section. There is a second section which also has an inner surface, an outer surface, and at least one longitudinal edge. Disposed along a longitudinal edge of the two sections is a hinge element that forms an axis of rotation for folding the two sections together. The energy absorber also includes a retaining device attached to a surface of one of the sections configured to attach the molded energy absorber to the pillar.
Another aspect of the invention provides a vehicle sun visor that comprises a first section having an inner surface and an outer surface, and at least one longitudinal edge. Integrally molded onto a surface of the first section is a plurality of telescopically crushable tubular elements that are sufficiently telescopically crushable to absorb impact energy. The sun visor also includes a second section having an inner surface and an outer surface and at least one longitudinal edge. Disposed along a longitudinal edge of the two sections is a hinge element that forms an axis of rotation for folding the two sections together.