Abstract: An automotive instrument panel having a concealed airbag. A molded substrate having first and second surfaces and an aperture therethrough receives an airbag. A curved metal door is secured to the second surface of the substrate by a plurality of fasteners extending through the substrate. The metal door has a generally U-shaped slot with first and second ends being spaced apart a distance greater than the length of the aperture. The slot is positioned radially outwardly of the aperture. The door also has a plurality of indentations to maintain a curved shape conforming with the surface of the substrate. A molded covering overlies the second surface and the door and is secured thereto with an intermediate layer of foam. A foam gasket overlies the slot between the door and the substrate. A foam impermeable layer is placed between the gasket and door to prevent injected foam from impregnating the foam gasket and interfering with the opening of the door.

Abstract: A method of manufacturing a panel having a foam interlayer. A flexible cover is placed adjacent a first mold in an open tool. A rigid substrate is placed adjacent a second mold, or alternately, is place atop the flexible cover in the first mold, of the opened tool. The first and/or second molds are electrically isolated from one another and from the associated manufacturing equipment. A vacuum draws the cover against the first mold and retains the cover in position during the manufacturing operation. The tool is moved to a closed position and the cover is positioned juxtaposed the substrate. The cover and substrate are positioned a distance apart thus creating a space therebetween. A vacuum is created in the space and a radio frequency (RF) electric field is applied between the first and second molds. The RF electric field causes a plasma to be created within the space. The plasma activates both the cover and the substrate. While the space is still under vacuum, a foaming material is injected into the space.