Land vehicles – Wheeled – Attachment
Reexamination Certificate
2000-01-13
2001-04-03
Rice, Kenneth R. (Department: 3611)
Land vehicles
Wheeled
Attachment
C280S731000
Reexamination Certificate
active
06209905
ABSTRACT:
TECHNICAL FIELD
This invention relates to a plastic air bag cover having a flexible decorative badge attached thereto and methods of making same.
BACKGROUND ART
Conventional air bag covers used in conjunction with occupant restraint systems may sometimes include decorative badges or ornaments attached thereto which are either formed integrally with or separate from the air bag cover. Such badges may take the form of a logo or mark representing a vehicle make, model, manufacturer, or the like. These decorative badges are aesthetically pleasing and help to enhance the overall appearance of the interior of the automotive vehicle. Since an air bag cover moves away from the steering column during inflation of the air bag, the associated decorative badge should be securely attached to the cover so that it does not come off during deployment and operation of the air bag.
Commonly, such decorative badges have an annular, symmetrical shape and are attached to the center of the air bag cover. Such badges may also be functional, and may for example be used as a horn interface on the air bag cover for actuating the automobile horn. More particularly, the switch for activating the horn is typically disposed in the area behind the decorative badge and therefore the badge must be depressed or otherwise be subjected to a force, however minimal, in order to activate the horn switch. Given the design of the badge and the types and thicknesses of materials used to form the badge, the horn switch may require relatively significant force in order to be actuated. Such relatively significant force may be required with badges having hard substrates or with metallic badges, such as those formed of aluminum having a decorative design painted or otherwise placed thereon.
Also, if the badge is other than a traditional annular badge, it may be difficult to maintain the attachment between the badge and the air bag cover across its contact area, particularly during horn actuation. In other words, for a relatively hard, non-annular badge, one or more portions of the badge may deflect upwards if another portion of the badge is depressed. Further, conventional air bag covers typically include annular or arcuate surfaces, and affixing the decorative badge to these designated surfaces may sometimes be difficult.
The prior art discloses various method of attaching an ornament to an air bag cover. For example, U.S. Pat. No. 5,678,851 to Saito discloses an air bag module cover which includes a cover member, an ornament on the cover member, and a rigid ornament-mounting structure including a fastener and a retainer. In one embodiment, a connecting film which fixes the ornament on the cover member has a membrane-type switch.
U.S. Pat. No. 5,529,336 and 5,487,557 issued to Eckhout disclose an air bag cover having a decorative applique fastened thereto. The decorative applique is disposed adjacent the tear seam in a non-overlapping fashion to prevent any interference with the inflation or exit of the air bag upon operation. The decorative applique includes a thin plastic layer extruded onto a decorative applique film. The decorative applique assembly is attached to the air bag cover by inserting connecting towers extending from the rear surface of the applique through fastening apertures which extend completely through the front cover of the air bag cover. A portion of the connecting tower extends out from the fastening aperture so that it may be deformed to form a retaining member larger in diameter than the fastening aperture so as to affix the applique to the air bag cover. The preferred method of deforming the portion includes applying a stream of heated air to the portion to melt the portion and then applying a cold stake directly to the melted portion to form the retaining member.
U.S. Pat. No. 4,139,664 issued to Wenrick discloses an elongated extruded strip adapted to be mechanically secured to a slotted sheet-like substrate. A thermoplastic material is continuously extruded in any desired cross-sectional configuration including a rear face having at least one rearwardly projecting rail. Longitudinally spaced apart sections of this rail are removed to provide longitudinally spaced rearwardly projecting teeth which enable mechanical securement of the extrusion to a supporting substrate having slots through which the teeth are extended.
U.S. Pat. No. 4,769,100 to Short teaches a method of applying a carrier film pre-printed with metallic paint to an automobile body panel in a vacuum forming process.
While the prior art has addressed the attachment issue in various forms, there still exists a need for an inexpensive and simple method of making an air bag cover having a decorative badge secured thereto, particularly for a badge which is non-annular. The badge should be fastened to the air bag cover across its surface area in a secure manner and should accommodate deflection when force is exerted upon it. The badge should permit actuation of switches located behind the badge without significant force. The badge should be fastened to the air bag cover by a method that allows a smooth surface and neat appearance. In addition, the badge should be affixed to the cover in such a way as to prevent it from separating from the front cover when the air bag deploys.
DISCLOSURE OF THE INVENTION
An object of the present invention is to provide a flexible badge for an air bag cover.
It is thus a general object of the present invention to provide an air bag cover having a flexible decorative badge secured thereto and a simple, inexpensive method of making same.
It is another object according to the present invention to provide an air bag cover having a decorative badge which is non-annular, non-symmetrical, and/or elongate in shape and design.
It is still another object according to the present invention to provide an air bag cover having a decorative badge which acts as a switch interface, such that the switch interface does not require significant force to actuate.
It is yet another object according to the present invention to provide a badge for an air bag cover which has the durability and strength necessary to support varying applications yet comply with styling and aesthetic requirements.
It is another object according to the present invention to provide a multiple-component badge that is assembled together and then assembled with the air bag cover.
In carrying out the above object and other objects of the present invention, a flexible decorative badge for an air bag cover is provided. The flexible badge is preferably a foil-covered plastic part. The foil-covered plastic part also includes a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to an outer surface of the at least one foil-receiving portion to form the automotive interior foil-covered plastic part. The resulting part has an aesthetically pleasing appearance. In one embodiment, the foil layer is a chrome layer.
More particularly, the present invention provides an air bag cover assembly which is adapted for mounting on a motor vehicle. The air bag cover assembly includes a plastic substrate which is adapted to enclose an uninflated automotive air bag and a switch. The substrate has an outer surface and an inner surface. The outer surface has a recessed portion which defines therebehind a switch location area. The air bag cover assembly also includes a badge which is bonded to the substrate and includes a relatively soft plastic preform which is compatible with the substrate and a foil top layer. The badge is shaped correspondingly to be received in and secured to, preferably permanently, to the recessed portion of the substrate and defines a switch interface for actuating the switch. The actuation occurs by applying pressure to the badge at it front outer surface. In various embodiments, the preform has a relatively elongated shape, an unsymmetrical shape, or a non-annular shape.
In another embodiment, the preform and the foil top layer are compatible so that diffusion occurs therebetween, and the top foil laye
Murar Jason T.
Preisler Darius J.
Brooks & Kushman P.C.
Patent Holding Company
Rice Kenneth R.
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