Abstract: A dash panel structure and method for forming such structure having an outer skin layer overlying a layer of foam cushioning material with a dimensionally stable support panel disposed below the foam cushioning material. A break-out pattern is applied across the surface of the substrate panel and into the overlying foam cushioning material in a pattern substantially corresponding to the desired deployment path of an underlying air bag cushion. The break-out pattern formed across the substrate panel is substantially aligned with a corresponding deployment opening pattern of grooved construction extending across the inner surface of the skin layer such that the deployment of the air bag cushion may be carried out at a controlled defined location within the dash panel structure.

Abstract: A skin layer for covering a dash panel structure in overlying relation to an air bag cushion assembly. The skin layer is of a multi-layered construction including a top layer of virgin polymeric material forming a show surface of controlled predefined color across the vehicle dash panel and an underlying layer of regrind material formed from the scraps of material generated during molding and trimming of the dash panel covers. A tear seam may be scored across the underside of the skin extending into the underlying layer of recycled material in a desired break-out pattern for the air bag cushion. The skin layer may be disposed across an underlying layer of foam which in turn is disposed across a supporting panel structure.

Abstract: According to the present invention, an instrument panel having an instrument panel cover including a hidden deployment region integrally formed within an inner surface thereof by an ultrasonic embossing process is provided. More specifically, the deployment region comprises at least one and preferably a plurality of scores or cuts formed in the inner surface according to a predetermined pattern. The scores represent weakened portions of the instrument panel cover designed so that the force of an inflating air bag cushion causes the instrument panel cover to separate along the scores to thereby provide an opening for the inflating air bag cushion to deploy therethrough and be directed into the passenger compartment of a vehicle. The deployment region may be defined by any number of scores and therefore may have a variety of patterns, including but not limited to “H” pattern, “U” pattern, and “I” pattern.

Abstract: An air bag cover assembly for use in an instrument panel of an automotive vehicle and including a displaceable door structure which lifts clear of the surrounding cover structure at an initial stage of air bag deployment prior to undergoing tethered rotation by one or more extensible tethering elements thereby substantially avoiding contacting relation between the door structure and adjacent portions of the cover structure and reducing stress on the nonmoving components.

Abstract: A skin layer for covering a dash panel structure in overlying relation to an air bag cushion assembly. The skin layer is of a multi-layered construction including a top layer of virgin polymeric material forming a show surface of controlled predefined color across the vehicle dash panel and an underlying layer of regrind material formed from the scraps of material generated during molding and trimming of the dash panel covers. A tear seam may be scored across the underside of the skin extending into the underlying layer of recycled material in a desired break-out pattern for the air bag cushion. The skin layer may be disposed across an underlying layer of foam which in turn is disposed across a supporting panel structure.

Abstract: A dash panel structure and method for forming such structure having an outer skin layer overlying a layer of foam cushioning material with a dimensionally stable support panel disposed below the foam cushioning material. A break-out pattern is applied across the surface of the substrate panel and into the overlying foam cushioning material in a pattern substantially corresponding to the desired deployment path of an underlying air bag cushion. The break-out pattern formed across the substrate panel is substantially aligned with a corresponding deployment opening pattern of grooved construction extending across the inner surface of the skin layer such that the deployment of the air bag cushion may be carried out at a controlled defined location within the dash panel structure.

Abstract: According to the present invention, an instrument panel having an instrument panel cover including a hidden deployment region integrally formed within an inner surface thereof by an ultrasonic embossing process is provided. More specifically, the deployment region comprises at least one and preferably a plurality of scores or cuts formed in the inner surface according to a predetermined pattern. The scores represent weakened portions of the instrument panel cover designed so that the force of an inflating air bag cushion causes the instrument panel cover to separate along the scores to thereby provide an opening for the inflating air bag cushion to deploy therethrough and be directed into the passenger compartment of a vehicle. The deployment region may be defined by any number of scores and therefore may have a variety of patterns, including but not limited to “H” pattern, “U” pattern, and “I” pattern.

Abstract: An instrument panel cover arrangement is used for covering an air bag module mounted beneath an instrument panel cover in a vehicle. The arrangement includes a rigid substrate forming the instrument panel cover and a cover plate overlying the substrate in the location of the underlying air bag module and securely attached to the substrate. The cover plate includes outer plate edges. The substrate includes a plurality of cut lines generally defining an air bag deployment opening and extending entirely through the substrate. The cut lines are at a location spaced inwardly from the outer plate edges of the cover plate such that upon air bag deployment, the outer plate edges are separated from the substrate by the force of the deploying air bag. Preferably, the cut lines extend entirely through the substrate to define a major substrate portion and a minor substrate portion.