Abstract: An integral deployment door in a panel of an airbag assembly which covers and conceals an airbag module. The molded panel having a front surface layer, a foam core, and a rear surface substrate has notches therein in alignment with the proposed tear region or sides of the deployment door. Tabs are provided which extend upwardly into the foam core along the sides of said deployment door and in alignment with the notches. The notches and tab construction weaken the tear region and concentrates the stresses along the sides of the deployment door to reduce the force required to open the deployment door and to reduce the fragmentation of the foam core due to the separation of the door from the rest of the panel.

Abstract: An essentially unitary airbag cover assembly is provided for concealing an airbag module. The cover has a vehicle panel with a front surface, a foam core and panel substrate with a dropped lip or shelf on a distal end thereof. A deployment door incorporated in the panel is hinged to the panel along one side thereof with at least one of the remaining sides of the door resting in the panel on the dropped lip or shelf of the panel substrate. The deployment door and panel are substantially the same thickness, and the shelf is dropped such that when the deployment door is positioned on the dropped shelf in the panel substrate, the door and panel are on the same level and there is no need for a connection between the panel and deployment door aside from the hinged side of the door.

Abstract: A deployment door positioned in a panel of a vehicle is opened by an airbag module located rearwardly of the deployment door. Apparatus is provided for detaching the door at a tear region from the remaining area of the panel, thereby providing a doorway outlet through the panel for the passage of an inflating airbag. A tear structure has a distal end in the form of an outwardly rounded bump cutter positioned and extending outwardly toward the tear region and a front surface of the panel, thereby reducing the distance of travel of the cutter through the foam in the panel to the tear region which reduces the force required to tear the foam. The outwardly rounded bump of the tear structure in one embodiment may be in the form of a closed loop. The deployment door may be completely contained within and surrounded by the panel before opening or may have one edge bordering on the edge of the panel.

Abstract: In a vehicle airbag installation in which a deployment door in a panel becomes detached along a tearable region of the panel for creating an outlet in the panel through which an inflating airbag deploys, apparatus for detaching the deployment door at such a tear region includes a cutter/ripper which is flat-lying in an inactive position. During deployment of the airbag a cutting part of the cutter/ripper is pushed forwardly for swinging into an upright active position for detaching the deployment door. This forward swinging involves a hinge-like bending or folding of an intermediate region of the cutter/ripper causing two simultaneous components of motion. In a first motion, the cutting part is moving away from the outlet being created thereby compressing and inhibiting fragmentation of nearby core foam in the panel. In a second motion the cutting part extends forwardly into a confining position for retaining core foam between front and rear surface layers of the panel.

Abstract: A fastening method and apparatus for attaching an automotive vehicle instrument panel air bag deployment door, an air bag module cover, to a passenger air bag module reaction canister. The apparatus provides a reliable cover release mechanism during an air bag deployment while allowing relative flexibility between the cover and reaction canister. The flexibility feature eliminates tolerance stack up problems by allowing the cover to locate off the instrument panel where it is intended to fit.