VEHICLE BODY COMPONENT WITH INTEGRATED CRASH SENSOR

• US 20110169251A1
• Filed: 01/11/2011
• Published: 07/14/2011
• Est. Priority Date: 01/11/2010
• Status: Abandoned Application

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Arndt, Thomas, Hagen, Markus
• Application Number:
  US13/004,290
• Publication Number:
  US 20110169251A1
• Time in Patent Office: Days
• US Class Current: 280/735
• CPC Class Codes: B60R 19/483 with obstacle sensors of electric or electronic type
• CPC Class Codes: B60R 25/00 Fittings or systems for preventing or indicating unauthorised use or theft of vehicles locks for vehicles E05B77/00-E05B85/00

Abstract

A crash sensor for use in a safety system of an automotive vehicle is molded directly into a body component, with no intervening housing being provided. The body component may be a vehicle cross member, such as for reinforcing a radiator grill opening. The crash sensor is molded into the body component together with connections and/or connecting lines and/or plug-in connections and/or electronic circuit board. The crash sensor may be encased in a protective layer prior to being molded into the body component.

Claims

1. A body component for a motor vehicle comprising:

a core composed of a structurally rigid material;

an outer layer molded over at least a portion of the core and composed of a plastic material; and

a crash sensor molded into the outer layer.

2. The apparatus of claim 1, further comprising connections associated with the crash sensor, the connections molded into the outer layer together with the sensor.

3. The apparatus of claim 2, wherein the connections comprise at least one of a connecting cable, a connecting line, a plug-in connection, and an electronic circuit board.

4. The apparatus of claim 1, wherein the crash sensor is molded into the body component when already molded into a protective layer.

5. The apparatus of claim 4, wherein the protective layer is made of a material that is fusible under conditions of the molding-in process of the crash sensor.

6. The apparatus of claim 3, further comprising a seal molded integrally with the crash sensor and surrounding the connections at their exit from the body component.

7. The apparatus of claim 1, wherein the crash sensor is molded form-fittingly into a corresponding recess of the body component.

8. The apparatus of claim 1, wherein the body component is a structural cross member.

9. An instrumented body component for a motor vehicle comprising:

a structural component having a rigid core and a plastic outer layer overlying, at least partially, the core; and

a crash sensor molded into the outer layer.

10. A process for manufacturing a body component for a motor vehicle comprising:

providing a core made of a structurally rigid material;

providing a crash sensor; and

at least partially encasing the core and the crash sensor in a coating made of a moldable plastic material.