Abstract: An air bag cover assembly including an air bag deployment concentrator such as a chute and first and second integrally hinged air bag doors is provided wherein a tear seam is located both inside and outside a channel of the chute. The tear seam interconnects the air bag doors to allow selective air bag deployment through a weakened area formed by the tear seam and portions of the film sheet immediately adjacent the weakened area. The assembly also includes first and second sets of hinges for hingedly connecting the first and second air bag doors, respectively, to a front panel both inside and outside the channel to facilitate pivotal movement of the air bag doors away from the air bag to allow deployment of the air bag through the channel, through the weakened area and through the portions of the film sheet during impact of the vehicle.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: The invention relates to reinforced composite inner roof panels of the sandwich-type having a cellular core. In a method for making a inner roof panel of the invention, a stack is formed that is made up of: an upper skin made of a reinforced thermoplastic material; a cellular core made of a thermoplastic material; and a bottom skin made of a reinforced thermoplastic material. The upper and lower skins and the cellular core are formed together and have regions of reduced thickness and regions of increased thickness that may provide head impact absorbing characteristics or form structural components of the passenger compartment. Examples of structural components that may be formed include HVAC ducts, wiring conduits, video display panel mounts or air bag receptacles.