Abstract: The driver's side airbag cover of an automotive airbag module is of one-piece, as opposed to layered, construction. It carries keypads within its active region which control function switches. The keypads are housed in openings which are backed by relatively rigid panels. The function switches are membrane switches sandwiched between the keypads and their respective panels.

Abstract: A plurality of spaced pairs of stakes are molded on the back of an airbag module cover. A horn switch assembly which is to be mounted on the back of the airbag module cover has a plurality of spaced pairs of openings along the perimeter thereof which are complementary to and are adapted to receive the spaced pairs of stakes on the cover. Subsequent to the positioning of the pairs of stakes in the complementary pairs of openings, the distal ends of the stake pairs are formed into a unitary bridge by heating. The bridge shaped heat staking thus employed thereby locks the horn switch on the back of the airbag module cover to prevent separation of the switch and cover on the deployment of the airbag and provide a much stronger attachment than standard methods of heat staking.

Abstract: An airbag module cover having downwardly extending sidewalls is mounted in the base of an airbag housing. The base has downwardly extending peripheral legs thereon having inner and outer walls forming a generally U- or V-shaped integral groove at the lower extremity thereof. The legs have locking tabs positioned above the grooves which tabs are adapted to protrude into or through the sidewalls of the cover. When the sidewalls of the cover are locked in the grooves of the legs, the inner and outer walls of the legs provide lateral support for the sidewalls for preventing separation of the cover sidewalls from the housing during airbag deployment.

Abstract: A membrane horn switch has a flexible thin front plate and a rigid thick back plate. The plates are coated with a conductive layer which are separated by dielectric material applied to either or both plates. The plates are attached together around their perimeters using a pressure sensitive adhesive. The switch is attached directly to an airbag cover, eliminating the need for external backing other than that which is provided by the rigid back plate of the switch.

Abstract: An airbag cover is provided with a membrane horn switch which is more reliable than prior art switches. A portion of the cover is thinned to provide a flexible horn actuation area. The membrane switch is mounted against the inner surface of the horn actuation area and is backed by a rigid panel mounted to the cover.

Abstract: A plastic cover for an air bag of a vehicle occupant restraint system is designed so that the tear lines forming the bag releasing doors create the door hinges at the outer margins of the cover. Where the outer margin is curved, a thinned region permits the hinge axis to flatten. Safety corners prevent tearing of the cover material through the hinge region.