Abstract: An inflatable restraint deployment system includes a simplified hold-down assembly for fastening an air bag door in a tamper-proof closed position. The deployment system includes an air bag door pivotally supported adjacent an air bag deployment opening in an automobile dashboard and two fasteners that releasably secure the door in a closed position over the air bag deployment opening. The fasteners each include an elongated shaft portion that either extends integrally upward from an air bag canister flange or integrally downward from an air bag door substrate. The fasteners are aligned in the direction of door movement. Each fastener shaft portion extends through one of a pair of fastener holes formed either in the air bag door substrate or in the canister flange. A fastener flange extends outward from around the shaft portion of each fastener and engages a rim that defines one of the fastener holes.

Abstract: A vehicle interior trim component, such as a glove compartment or console door, and its method of fabrication includes an outer flexible shell having a peripheral contoured return flap captured within a peripheral gap provided between insert and backing panels of the component. Foam is injected into a space between the outer shell and insert panel and any gases and excess foam are allowed to escape from the foam space into an adjacent overflow chamber in a controlled manner through the gap while the return flap seals the assembly against external leakage of such excess foam.

Abstract: A method for fabricating plastic interior trim components having an insert with openings therein joined to a composite member including a shell and a foam layer, the method including die punching a hole through the shell and foam layer and die punching an edge extension on the shell to a predetermined parametric form; providing a press that is operable to compress a part therebetween and including a first platen and a second platen moveable between opened and closed positions with respect to one another; providing an insert having an opening; supporting the insert on one of said first and second platens and applying adhesive on a surface of the insert; loading the composite member on the other of said first and second platens so that the foam layer thereof is facing the adhesive sprayed insert inboard of the die cut edge extension; closing the press to compress the adhesive sprayed surface against the foam layer of the composite member for adhering the insert only to the foam layer without leakage of foam thr

Abstract: A door cover assembly for concealing a supplemental inflatable restraint (SIR) system of an automotive interior trim component includes a substrate having a door section in which formed depressions are provided to strengthen the door. The depressed regions are filled with a secondary foam insert to level the outer surface of the substrate. A primary foam layer overlies the substrate and is covered by an outer vinyl shell. The leveling of the substrate by the secondary foam insert eliminates "show through" of the depressed regions on the outer Class A surface of the vinyl shell.