TECHNICAL FIELD The invention described hereafter is the shock-absorbing air-cushioned buffer for vehicles. The main process manufacturing the buffer is as follows;

First, forge a base sheet having embossed bumps using several kinds of moulding. Then insert unit pressurized air tubes and elastic material into the bumps. The third step is to place a flat sheet rigged with reinforcement material and fixing clips on the bumps and secure them airtight. Place a cover on the secured bumps in the way that provides empty space between the two.

The upper side of the cover is cloaked with elastic resin only to be formed into a designed shape. The process is completed with refractory treatment of the buffer.

BACKGROUND ART

Generally a vehicle is loaded with several shock-absorbing devices; bumpers attached front and rear sides of a car, urethane foams, plastic devices, and air bags inside. When either side of the vehicle is hit by another car, the car-paint peels off and sometimes the sidelong part of the automobile is crushed only to injure either a driver or passengers. Similarly, when a vehicle collides with another one on a driveway, bumpers do not absorb enough shock so that the driver and passengers are often seriously injured from the colliding shock. Even worse, the air bags popped out on time do not prevent the driver from bumping his head on the headrest or the roof of the vehicle and eventually hurting himself.

In order to cope with above-related problems we have already filed for the authorities' approval of two items; a shock-absorbing device applied to the bumper of automobiles (Korea Utility Model Notification No. 94-7460) and the manufacturing technology of shock absorbing air-cushioned sheet (Korea Patent Notification No. 95-12440 and Intemational Application No. PCT/KR94/00116). However, the first item (a shock-absorbing device applied to a bumper) was found to have some problems. It is made of a base sheet having embossed bumps formed by vacuum moulding, to begin with. Then place a flat sheet on the base sheet and fix it using high-frequency waves. In this way the air within the bumps are safely secured. An air valve is attached

to the secured bumps so that the air can be pumped thereinto. A cover is mounted on these bumps. The final step is cloaking the cover with elastic resin. After all, however, the completed bumper had only one air layer, failing to provide ideal shock absoφtion. The process of manufacturing the second item (shock-absorbing air- cushioned sheet) which was the modified version of the first invention is as follows ; First, place several air tubes on the flat sheet and fuse one end of the tubes to the sheet. Fuse again to the sheet several points between the two ends and the other end, forming several air-filled bumps. Finally, the bumps are coated with elastic resin including polyurethane. We, however, face some problems here, too.

The air-filled bumps are formed using only one air tube unit, giving less cushioning than expected. Another unnerving matter is that it is impossible to pump the air into the tubes when it is needed. The completed invention has no device to instantly force the compressed air out of the tubes, which is required in case of serious collision, posing another problem. After all the burst tubes greatly reduces the buffering effect. Meanwhile, the previously invented shock- absorbing bumper(Japan Utility Model Notification No. 2-13851) is designed to buffer the colliding shock by inserting the sheet containing air layers between the bumper's beam and the cover. Similar to the above item, this invention has no device for pumping the air or adjusting the air pressure. After all, the problem is that the air layer seated inside the bumper cannot effectively buffer the shock in case of a vehicle's hitting a pedestrian or in minor cases.

DISCLOSURE OF INVENTION

This invention is the modified form of previously-filed items, designed to solve their problems. The major characteristics of the invention are as follows; To begin with, the base sheet has bumps within which air tubes of different air pressure and size along with elastic material are seated. Then place a flat sheet rigged with reinforcement material and fixing clips on the bumps and secure the two (the sheet and the bumps) airtight. On this mount and fix a cover made of soft material that endures the impact of shaφ object. This cover is coated with elastic resin to be shaped into a designed form. The finished buffer can be applied by fixing device to in- and outside of a car. For some variation, the bare cover without resin-coating may be formed into

a desired shape. To maximize the buffering effect, some of unit pressuπzed air tubes may be wrapped with textiles that keep the tube from inflating. A safety valve that reacts to a given degree of impact is inserted into wrapped air tubes.

When given a strong impact, this valve instantly forces the pressurized air out of the units, preventing a vehicle from bouncing back. In order to cope with the functional deterioration in case of the bursting of the air tubes, elastic material is inserted into the bumps and between each bump additional air tubes are seated, enabling more effective shock-absorption. (See Fig. 2)

Followings are detailed description of attached pictures. The invention described here is the shock-absorbing air cushion buffer for vehicles(110). The main process of manufacturing the buffer is as follows;

First, forge a base sheet(5) having embossed bumps(2) using several kinds of moulding. Then insert unit pressurized air tubes(8) and elastic material(19) into the bumps(2). The third step is to place a flat sheet(1) equipped with reinforcement material(18) along with fixing clips(6) on the bumps and secure it airtight. Place a cover(14) on the secured bumps(2) in the way that provides empty space(7) between the two. The upper side of the cover is cloaked with elastic resin(4) only to be formed into a designed shape. The finished buffer can be loaded on the various transportation vehicles which often come under strong impact as well as in- and outside of an automobile.

A soft-material cover without resin-coating(4) may be adopted alone or a protection panel(12) can be employed. As material of reinforcement material(18) steel or light-weight, blow-moulded plastic may be used. The plastic reinforcement materialmakes the assembling much easier and ensures enhanced safety.

BRIEF DESCRIPTION OF DRAWINGS. Fig. 1 is the front sectional view of the invention. Fig. 2's A and B are the longitudinal section of the invention. Fig. 3's A and B are the perspective of the status without elastic resin-coating Fig. 4 is the longitudinal section excluding the resin of elasticity. Fig. 5 is the longitudinal section displaying the second embodiment of the invention. Fig. 6 is the longitudinal section displaying the third embodiment of the invention.

invention. Fig. 7 is the longitudinal section displaying the fourth embodiment of the invention. Fig. 8's A and B are the longitudinal section displaying the fifth embodiment of the invention.

Fig. 9 is the longitudinal section displaying the sixth embodiment of the invention. Fig. 10 is the enlarged sketch of major parts including the profile of a car loaded with the invention and the roof. Fig. 11's A and B are the enlarged section of the line A-A after a bumper is rigged with the invention.

BEST MODE FOR CARRYING OUT THE INVENTION The first method of manufacturing the "Air cushion buffer for absorbing shock(110)" is displayed in the Fig. 4. Forge a base sheet having embossed bumps using several sorts of moulding. Then insert unit pressurized air tubes (8) and elastic material(19) into the bumps(2). The next step is to place a flat sheet(1) with reinforcement material(18) and fixing clips(6) on the bumps and secure it to the bumps. A valve regulating air-insertion is installed at the secured seams. Between the bumps(2) several beams are seated. Then a folded support sheet(9) is fused to these beams. By doing this when pressurized air (not appears in the picture) is inserted by the impact sensor(not appears) only to form an air bags within the space 2(7). Upon the fused folded sheet, fix additional cover(14) so slightly that it can be split apart by the inflating air bags in the space 2(7). This additional cover(14) is cloaked with elastic resin(4) to be formed into a complete buffer. Patterns can be engraved on the surface of the elastic resin(4), which underwent refractory treatment. The finished buffer can be adopted to a steering wheel or headrests as well as other inner and outer parts of an automobile. Aiφlanes -especially for their interior safety- can benefit from this buffer, too. In a variation a cover(14) free from elastic resin-coating may be formed into a complete buffer. For the reuse of the buffer vacuum suction device can be installed to turn the air bags, inflated by the impact, in the space 2(7) to its original shape.

The second method of manufacturing the invention is displayed in the Fig. 5. Forge a base sheet(5) having embossed bumps(2). Some of unit pressurized

air tubes(8) are wrapped with textiles(21) that prevents the tubes from inflating by the insertion of pressurized air. Then a safety valve(16), which is activated by the impact sensor (not appears in the picture), therefore bursts tubes, is mounted on the textile-wrapped air tubes. Then these air tubes are inserted into the bumps, upon which a flat sheet(1) with reinforcement material(18) along with fixing clips(6) is mounted and secured airtight. To these secured bumps folded support sheet is fused so that the air bags in the space 2(7) can be inflated by the air forced out of the pressurized air tubes(8) by the safety valve. Upon the fused folded sheet, fix additional cover(14) so slightly that it can be split apart by the inflating air bags in the space 2(7). This additional cover(14) is cloaked with elastic resin(4) whose surface underwent refractory treatment to be formed into a complete buffer. The finished buffer is employed to the in- and outside of a vehicle by the fixing clips(6). In this method the cover(14) without resin-coating is preferred. The third method of manufacturing the invention is displayed in the Fig. 6.

Forge a base sheet(5) having embossed bumps(2) into which safety valve(16j- rigged unit pressurized air tubes are inserted. The bumps are mounted with a flat sheet(1) having reinforcement material(18) and fixing clips(6). This allows the air bags in the space 2(7) to inflate in cases. The base sheet(5) and the flat sheet(1) are fused airtight. Between the secured bumps(2) additional air tubes(8) are seated and these tubes are fixed by a cover(14). The cover(14) is coated with elastic resin(4) to be formed into a buffer. The finished buffer can be loaded on front and rear frame of a vehicle by means of fixing clips(6). Otherwise the buffer can be seated inner or outer part of the soft bumper- case(13). It is also possible to adopt only a soft cover(14) without resin- coating. A device which automatically adjusts the air-pressure will help the buffer to ensure more safety.

The fourth method of manufacturing the invention is displayed in the Fig. 7. Forge a base sheet(5) having embossed bumps(2) upon which a flat sheet(1) having reinforcement material(18) and fixing clips(6) is mounted. Unit pressurized air tubes(δ) and elastic material(19) are inserted into the bumps(2) formed on the base sheet(5). Then a support sheet(9) is fixed on the flat sheet(1) so that the space 2(7) can be formed. A valve(10) that pushes the air in and out of the space 2 is employed to the support sheet(9). The flat sheet(1) and the base sheet(5) are secured together airtight. When the

completed buffer is seated inside a car or a helmet, the size can be adjusted by regulating the amount of air within the space 2(7). Sometimes resin-coated bumps can be used alone. The fifth method of manufacturing the invention is displayed in the Fig. 8. Forge a base sheet(5) having embossed bumps(2) and unit pressurized air tubes(8) are inserted thereinto. A safety valve(16) is added to a flat sheet(1) which has reinforcement material(18) as well as fixing ciips(6). The reinforcement material(18) and a base sheet(5) are secured airtight. The support sheet(9) is fused on the bumps(2) to sustain the space 2(7). Another cover(14) is mounted on the fused sheet(9). This cover is coated with elastic resin. The completed bumper is adopted either in- or outside of a bumper case(13). Otherwise, a bare cover without resin-coating can be used. Inserting additional buffering air tubes within the support sheet(9) would ensure more effective shock-absorption. Or a special protection layer(22) can be seated between the support sheet(9) and the cover(14) only to protect the sheet(9) from the impact of shaφ stuff. This guarantees enhanced function of the bumper(15). In some cases elastic resin(4) can be carved into a designed shape before being mounted on the cover(14)

The sixth method of manufacturing the invention is displayed in the Fig. 9. Like other methods, a base sheet(5) having bumps(2) formed by several kinds of moulding is forged first. The textile(21)-wrapped unit pressurized air tubes(8) along with a safety valve(16) are inserted into the bumps(2). Textile- wrapping of the tubes precludes the inflation of the tubes by the insertion of air. Then the bumps are fused airtight with a fiat sheet(1) having reinforcement material(18) and fixing clips(6). In the case that a safety valve(16) reacting to the impact forces the air out of the textile-wrapped tubes, the drained air reaches the valve(10) of shock-absorbing air-cushioned buffer(110) - shown in the Fig. 4 - only to inflate the air bags seated in the space 2(7). In some variation an impact-sensor can be attached to the finished bumper. The same sensor can be produced to detect a driver's voice alarming the danger, as well. In this case the sensor is seated inside of a car, providing more safety.

As described so far, this invention (the buffer) can be added to either in- or outside of a vehicle. Otherwise, as shown in the respective pictures, elastic resin(4) may be carved into a shape before being attached to the cover(14).

The "Air cushion buffer for absorbing shock," which can be employed not only inner or outer parts of a vehicle but airplanes, have a lot of benefits including the followings. As it is widely acknowledged, in car accidents many of serious injuries afflicting a driver or passengers are caused by the crushed hard plastic- or steel-made car parts. If a car's inner side of a roof or headrests, most of which are made of textiles or urethane foam, are produced using the above-related invention, the possibility of those injuries can be significantly reduced. Similarly if the invention is mounted on a vehicle, it saves the cost taken to replace a broken or crushed bumper with new one. Besides the manufacturing process is very easy and simple so that it is possible to reduces the manufacturing cost as well as the weight of the finished buffer.

To preclude the deterioration of the buffering effect caused by bursting of air tubes(8), the tubes can be effectively replaced by elastic material(19). Furthermore, given the increasing concern of environmental pollution, currently-used sponge and urethane which are not recyclable should be replaced in the long run. And bumpers need to be designed to reduce the impact on pedestrians hit by cars.

In this respect the invention, the air-cushioned buffer, may well be employed in manufacturing the safety-oriented vehicles in the future. Because it effectively absorbs much of collision-shock by allowing the air bags in the space 2(7) to instantly inflate. These air bags in the space 2 (7) can be acted by the voice-detecting sensor as well, effectively decreasing casualties. Actually the invention can be adopted into any parts vulnerable to the impact of a vehicle. It may be seated inside a car to prevent drivers' knee injury. Adopted to the sides, the double-layer pressurized air plays as impact bars to ideally buffer the impact.