Abstract: A method and apparatus is disclosed for forming a cover for an air bag deployment opening, the cover having a tear seam defined by a reduction in thickness of the cover. The cover can be formed as an unitary part of an outer skin layer for an automobile interior trim structure. The apparatus includes a thin shell having an inner surface upon which a thermoplastic material is cast to form the outer skin. A multiplicity of pins are disposed on and extend away from a backside thereof to transfer heat to the inner surface. The density of the pins is reduced on the portion of the backside of the shell proximate the portion of the inner surface upon which the tear seam of the outer skin is to be formed. The shell can be heated or cooled by using a plurality of nozzles to impinge heated or cooled air onto predetermined locations of the backside. A cover and tear seam construction is also disclosed.

Abstract: A method and apparatus is disclosed for forming a cover for an air bag deployment opening, the cover having a tear seam defined by a reduction in thickness of the cover. The cover can be formed as an unitary part of an outer skin layer for an automobile interior trim structure. The apparatus includes a thin shell having an inner surface upon which a thermoplastic material is cast to form the outer skin. A multiplicity of pins are disposed on and extend away from a backside thereof to transfer heat to the inner surface. The density of the pins is reduced on the portion of the backside of the shell proximate the portion of the inner surface upon which the tear seam of the outer skin is to be formed. The shell can be heated or cooled by using a plurality of nozzles to impinge heated or cooled air onto predetermined locations of the backside. A cover and tear seam construction is also disclosed.

Abstract: An SIR door and instrument panel are formed by adhering a single, unitary cover material over a preformed door insert member and separate preformed panel insert member. The insert members are sprayed with an adhesive and placed on a support member with the door insert member aligned with and raised above an opening in the panel insert member. The single, unitary cover material is laid over the insert members and vacuum formed thereabout. Thereafter, the cover material is trimmed from the door insert member. The door insert member and cover material are removed from support member. The instrument panel and supplemental impact restraint (SIR) door may thereafter be assembled.