Vehicle interior trim panel

[0001] 1. Field of the Invention

[0002] The present invention generally relates to a vehicle interior trim panel of a vehicle body structure. More specifically, the present invention relates to a vehicle interior trim panel having an assist grip handle projecting through the trim panel.

[0003] 2. Background Information

[0004] Vehicle structures are continually being improved for passenger safety. Most vehicles now include one or more airbags. Typically, an airbag includes an inflatable member that when deployed creates a cushioning bag or cushioning curtain to protect a passenger or passengers during impact events. Airbags are often installed in pillar structures within certain vehicles. For example, an airbag is sometimes installed in an A-pillar of the vehicle such that when the airbag inflates a cushioning curtain is formed between the vehicle passenger and a door and/or a portion of an interior roof of the vehicle. Many vehicles include an assist grip handle to assist passengers in entering and exiting the vehicle. These assist grip handles are often mounted to portions of pillars and/or roof rails that are next to a door opening. Typically, the assist grip handles are securely mounted to metal structural elements of the vehicle body with fasteners that extend through apertures in trim panels. Trim panels are usually provided over the metal structural elements of the vehicle body with the assist grip handles projecting through the trim panels to provide an attractive appearance. When an airbag is installed beneath a trim panel with an assist grip handle projecting through the trim panel, the trim panel needs to easily release from the metal structural element of the vehicle body upon deployment of the airbag. The interface between the trim panel and the assist grip handle should be configured such that the assist grip handle does not obstruct the deployment of the airbag.

[0005] In view of the state of the known technology, one aspect of the present invention is to provide an interface between a vehicle interior trim panel and an assist grip handle that desensitizes the gap condition between the vehicle interior trim panel and the assist grip handle while allowing the vehicle interior trim panel to easily release from the metal structural element of the vehicle body upon deployment of the airbag.

[0006] In order to carry out this aspect of the present invention, a vehicle interior trim panel is provided that mainly comprises a rigid trim portion and a first flexible trim portion. The rigid trim portion includes a first assist grip opening. The first flexible trim portion is attached to the rigid trim portion along an edge of the first assist grip opening with the first flexible trim portion at least partially covering the first assist grip opening of the rigid trim portion.

[0021] Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[0022] Referring initially to FIGS. 1 and 2, an interior portion of a vehicle 10 is illustrated that has a vehicle body structure 12 that includes a vehicle interior trim panel 14 in accordance with an illustrated embodiment. The vehicle body structure 12 further includes a pillar 16 and an assist grip handle 18. An airbag 20 is disposed between the vehicle interior trim panel 14 and the pillar 16. In the illustrated embodiment, the assist grip handle 18 is securely attached to the pillar 16, which constitutes a structural vehicle body section of the vehicle 10. The trim panel 14 covers the pillar 16, the airbag 20 and the connection of the assist grip handle 18 to the pillar 16. The assist grip handle 18 provides an assist grip that helps passengers get in and out of the vehicle 10. As shown in FIGS. 1 and 2, the pillar 16 is an A-pillar of the vehicle 10. Of course, the vehicle body structure 12 can be employed in other areas of the vehicle 10. The trim panel 14 is releasably secured to the pillar 16 such that the trim panel 14 moves away from the pillar 16 in response to deployment of a concealed airbag 20. In the illustrated embodiment, the assist grip handle 18 remains attached to the pillar 16 after deployment of the airbag 20.

[0023] As seen in FIGS. 1, 3 and 4, the trim panel 14 is configured to overlay a portion of the pillar 16 and conceal the airbag 20. As seen in FIG. 2, the trim panel 14 is also configured to at least partially breakaway from the pillar 16 in response to deployment (inflation) of the airbag 20. In particular, the trim panel 14 moves away from the pillar 16 by a sufficient distance away from the pillar 16 to allow full deployment of the airbag 20. In the illustrated embodiment, the trim panel 14 is restrained from moving away from the pillar 16 by no more than a predetermined distance as mentioned below.

[0024] As seen in FIGS. 5 to 11, the trim panel 14 mainly includes a rigid trim portion 22, a first flexible trim portion 24 and a second flexible trim portion 26. With the rigid trim portion 22 secured to the pillar 16, the first and second flexible trim portions 24 and 26 contact the assist grip handle 18 to fill any gap occurring in the interface between the assist grip handle 18 and the rigid trim portion 22. In other words, each of the first and second flexible trim portions 24 and 26 constitutes a grip assist gap hider that covers the gaps between the rigid trim portion 22 and the assist grip handle 18.

[0025] As best can be seen in FIGS. 7 to 9, the rigid trim portion 22 of the trim panel 14 is releasably secured to the pillar 16 by a pair of trim clips 30 and 32. The trim clip 30 engages a clip mating part 34 via a snap-fit, while the trim clip 32 engages a clip mating part 36. In the illustrated embodiment, the trim clip 30 is attached to the hidden backside surface of the rigid trim portion 22 by a tether part 38. Thus, as best seen in FIG. 13, the trim clip 30 and the tether part 38 form an integrated trim clip/tether. When the airbag 20 is deployed during a collision, the trim clip 30 separates from a base portion 38a of the tether part 38 so that a loop portion 38b of the tether part 38 can unfold. In other words, during deployment of the airbag 20, the trim clip 30 remains attached to the pillar 16 and the base portion 38a of the tether part 38 remains attached to the hidden backside surface of the rigid trim portion 22. However, the trim clip 30 also remains connected to the base portion 38a of the tether part 38 by the loop portion 38b of the tether part 38 which has unfolded to allow the trim panel 14 to move away from the pillar 16 by no more than a predetermined distance. The trim clip 32 is directly attached to the rigid trim portion 22 of the trim panel 14. The trim clips 30 and 32 are conventional clips that release from the clip mating parts 34 and 36 upon an application of a prescribed releasing force. When the airbag 20 is deployed, the airbag 20 applies a force that is greater than the prescribed releasing force of the trim clips 30 and 32. Preferably, the trim clips 30 and 32 mate with the clip mating parts 34 and 36 in a reinstallable manner such that the trim panel 14 can be repeatedly removed and reinstalled without the trim clips 30 and 32 and/or the clip mating parts 34 and 36 becoming damaged. Since trim clips and their clip mating parts are well known in the automotive field, the trim clips 30 and 32 and/or the clip mating parts 34 and 36 will not be illustrated and/or discussed in detail herein.

[0026] The rigid trim portion 22 is made of a thermoplastic polymer, such as polypropylene resin. The rigid trim portion 22 has a higher rigidity than the rigidities of the first and second flexible trim portions 24 and 26. The term “rigid” as used herein does not require complete inflexibility, but rather the term “rigid” means self-supporting and maintaining its shape with or without a predetermined degree of flexibility. The rigid trim portion 22 includes a first assist grip opening 44 and a second assist grip opening 46. The first and second assist grip openings 44 and 46 are formed in a peripheral edge 48 of the rigid trim portion 22 such that the first and second assist grip openings 44 and 46 are open at the peripheral edge 48 of the rigid trim portion 22. As discussed below, the assist grip handle 18 projects through the first and second assist grip openings 44 and 46.

[0027] The first and second flexible trim portions 24 and 26 are each formed of an elastomer. In other words, the first and second flexible trim portions 24 and 26 are formed of a soft pliable material such as Santoprene™. Thus, the first and second flexible trim portions 24 and 26 are more pliable than the rigid trim portion 22. In the illustrated embodiment, the first and second flexible trim portions 24 and 26 are initially flat pieces of rubber or other suitable resilient members prior to attachment to the rigid trim portion 22. However, once the first and second flexible trim portions 24 and 26 are attached to the rigid trim portion 22, the first and second flexible trim portions 24 and 26 conform to the contour of the rigid trim portion 22. For example, the first and second flexible trim portions 24 and 26 are attached to curved sections of the rigid trim portion 22 such that the first and second flexible trim portions 24 and 26 are curved after being attached to the rigid trim portion 22.

[0028] In the illustrated embodiment, the first and second flexible trim portions 24 and 26 are bonded to the rigid trim portion 22 by adhesive. Alternatively, the rigid trim portion 22 and the first and second flexible trim portions 24 are formed using an integrated two-shot molding method in which the rigid trim portion 22 is first molded and then the first and second flexible trim portions 24 and 26 molded directly onto the rigid trim portion 22 using an integrated mold. Also, as seen in FIG. 11, the rigid trim portion 22 can include several projections 22a that extend through the first and second flexible trim portions 24 and 26 to aid in securing the first and second flexible trim portions 24 and 26 to the rigid trim portion 22. The first flexible trim portion 24 is attached to the rigid trim portion 22 along an edge of the first assist grip opening 44 with the first flexible trim portion 24 at least partially covering the first assist grip opening 44 of the rigid trim portion 22. The second flexible trim portion 26 is attached to the rigid trim portion 22 along an edge of the second assist grip opening 46 with the second flexible trim portion 26 at least partially covering the second assist grip opening 46 of the rigid trim portion 22.

[0029] In the illustrated embodiment, the first and second flexible trim portions 24 and 26 are identical to each other. In particular, the first flexible trim portion 24 has a first assist grip receiving cutout 54 that is configured to receive the assist grip handle 18. Likewise, the second flexible trim portion 26 has a second assist grip receiving cutout 56 that is configured to receive the assist grip handle 18. The first assist grip receiving cutout 54 is formed at a peripheral edge 58 of the first flexible trim portion 24 such that the first assist grip receiving cutout 54 is open at the peripheral edge 58 of the first flexible trim portion 24. The second assist grip receiving cutout 56 is formed at a peripheral edge 60 of the second flexible trim portion 26 such that the second assist receiving cutout is open at the peripheral edge 60 of the second flexible trim portion 26. Thus, the first and second flexible trim portions 24 and 26 are generally U-shaped members that are individually secured to the rigid trim portion 22.

[0030] The first and second flexible trim portions 24 and 26 are offset from the peripheral edge 48 of the rigid trim portion 22 that includes the first and second assist grip openings 44 and 46. The first assist grip opening 44 extend parallel to the areas of the rigid trim portion 22 that is adjacent the peripheral edge 48 of the rigid trim portion 22 that includes the first and second assist grip openings 44 and 46. Preferably, the first and second flexible trim portions 24 and 26 are resilient members with a prescribed amount of self-supporting and shape maintaining properties. In other words, when the trim panel 14 is installed on the pillar 16, the first and second flexible trim portions 24 and 26 will bend and/or compress so as to conform to the surfaces of the assist grip handle 18 that are contacted by the first and second flexible trim portions 24 and 26. Also, when the trim panel 14 is removed from the pillar 16, the first and second flexible trim portions 24 and 26 will spring back to their original non-deformed (unstressed) state. In this manner, the trim panel 14 can be repeatedly removed from the pillar 16 and then reinstalled on the pillar 16 without adversely affecting the performance of the first and second flexible trim portions 24 and 26 acting as grip assist gap hiders. Thus, this configuration of the trim panel 14 solves the inherent problem that occurs at the interface of mating parts due to part to part variation and assembly tolerances. Also this configuration of the trim panel 14 minimizes undesirable sounds that might otherwise occur by relative movement of the trim panel 14 with respect to the assist grip handle 18 due to vibrations of the vehicle 10.

[0031] As seen in FIGS. 5 to 7, the pillar 16 is a structural part of the vehicle body that is made one or more pieces of sheet metal. The precise construction of the pillar 16 will vary from vehicle to vehicle. Thus, the precise construction of the pillar 16 will not be described and/or illustrated in detail herein. In the drawings, the pillar 16 is depicted as an A-pillar of the vehicle 10. Typically, A-pillars are structural portions of a vehicle located between a windshield and a vehicle door. However, it should be understood from the drawings and the description herein that the vehicle body structure 12 can be employed in other areas of the vehicle 10 such as a B-pillar or other area within the vehicle 10 where the assist grip handle 18 could be provided.

[0032] In the illustrated embodiment, as seen in FIGS. 7 to 12, the assist grip handle 18 is a shallow U-shaped member that has a gripping portion 62, a first end portion 64, a second end portion 66, a first attachment portion 68 and a second attachment portion 70. The assist grip handle 18 is formed of a rigid material, such as a hard plastic material. In the illustrated embodiment, the assist grip handle 18 is one-piece, unitary member that is formed of polypropylene resins. The first end portion 64 is disposed in the first assist grip receiving cutout 54 of the first flexible trim portion 24, while the second end portion 66 is disposed in the second assist grip receiving cutout 56 of the second flexible trim portion 26. When the trim panel 14 is installed on the pillar 16, the first and second flexible trim portions 24 and 26 will bend and/or compress so as to conform to the surfaces of the first and second end portions 64 and 66 of the assist grip handle 18. In the illustrated embodiment, the assist grip handle 18 is fixedly secured to the pillar 16 by a pair of fasteners 72 (e.g., two bolts). The fasteners 72 extend through apertures in the first and second attachment portions 68 and 70 and into respective threaded holes of the pillar 16.

[0033] As seen in FIG. 1, the airbag 20 is attached to an upper region of the inner pillar portion 30 in a conventional manner. The airbag 20 is preferably a safety device that is operatively connected in a conventional manner to sensors and/or a control device (not shown) that activates the airbag 20 in response to an impact or collision in a conventional manner. Preferably, the airbag 20 is an air curtain-type device dimensioned such that when deployed in response to vehicle impact, the airbag 20 inflates to a shape similar to an inflatable mattress or the like. As indicated in FIG. 2, once deployed, the airbag 20 takes on a rectangular like-shape forming a protective cushion between a passenger and the door and side window. It should be understood from the drawings and the description herein that the airbag 20 can also be configured to form a protective cushion between the passenger and the inner part of the roof of the vehicle 10. In other words, the specific dimensions and inflated characteristics of the airbag 20 are not limited to those depicted in FIG. 2, but can be specifically chosen depending upon the dimensions and characteristics of the vehicle 10 and requirements of current and proposed safety standards.

[0034] In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment(s), the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the vehicle body structure. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the vehicle body structure. The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

[0035] While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.