Abstract: An instrument panel for a passenger compartment of an automotive vehicle comprises a molded plastic substrate and a skin covering the substrate. The substrate has inner and outer surfaces, and is adapted to be mounted in the passenger compartment adjacent a windshield. The inner surface is adapted to receive an air bag chute assembly for deploying an air bag. The inner surface is inscribed by a door groove defining a deployment door at least partially tearing open to expel the air bag. The outer surface is inscribed by a hinge groove following a chord path bisecting the outer surface of the deployment door and configured to bend in response to an edge of the deployment door impacting the windshield. The impact force against the windshield is reduced while stiffness of the door against the air bag remains high to facilitate tearing open of the door by the air bag.

Abstract: An instrument panel for a passenger compartment of an automotive vehicle comprises a molded plastic substrate and a skin covering the substrate. The substrate has inner and outer surfaces, and is adapted to be mounted in the passenger compartment adjacent a windshield. The inner surface is adapted to receive an air bag chute assembly for deploying an air bag. The inner surface is inscribed by a door groove defining a deployment door at least partially tearing open to expel the air bag. The outer surface is inscribed by a hinge groove following a chord path bisecting the outer surface of the deployment door and configured to bend in response to an edge of the deployment door impacting the windshield. The impact force against the windshield is reduced while stiffness of the door against the air bag remains high to facilitate tearing open of the door by the air bag.

Abstract: An air bag housing includes a chute defining an upper perimeter with a first wall extending from the upper perimeter and a cover extending over the chute integrally from the upper edge. The cover defines a tear seam extending between opposite portions of the upper perimeter remote from the first wall and a hinge area extending between the opposite portions of the upper perimeter and disposed between the first wall and the tear seam.

Abstract: An air bag housing includes a chute defining an upper perimeter with a first wall extending from the upper perimeter and a cover extending over the chute integrally from the upper edge. The cover defines a tear seam extending between opposite portions of the upper perimeter remote from the first wall and a hinge area extending between the opposite portions of the upper perimeter and disposed between the first wall and the tear seam.

Abstract: An integrated air bag chute structure that provides means for providing automatic interlocking attachment of the chute to the substrate of an instrument panel. By inserting the air bag chute into a substrate aperture and utilizing slots, depressions and notches formed in the chute structure beneath a surrounding flange, the aperture edges are captured and retained to thereby lock the chute in place.

Abstract: An airbag assembly for a motor vehicle does not require any heat stakes and permits a deployment door to be formed in the interior panel without the need for scoring or other pre-weakening thereof. The airbag chute is constructed of plastic and includes a substrate facing surface. A door assembly includes a metal door and a plastic door plate. The door plate is positioned between the substrate and the door portion, and has a substrate facing surface. The substrate facing surfaces of the airbag chute and the plastic door plate are attached to the substrate. The substrate facing surface of the plastic door plate engages the substrate over a contact area to distribute a force imposed on the plastic door plate from the deployment of the airbag.

Abstract: An airbag assembly for a motor vehicle does not require any heat stakes and permits a deployment door to be formed in the interior panel without the need for scoring or other pre-weakening thereof. The airbag chute is constructed of plastic and includes a substrate facing surface. A door assembly includes a metal door and a plastic door plate. The door plate is positioned between the substrate and the door portion, and has a substrate facing surface. The substrate facing surfaces of the airbag chute and the plastic door plate are attached to the substrate. The substrate facing surface of the plastic door plate engages the substrate over a contact area to distribute a force imposed on the plastic door plate from the deployment of the airbag.

Abstract: A seamless passenger side inflatable restraint system for a motor vehicle includes an instrument panel having a deployment opening and a deployment door integral with the instrument panel and closing the deployment opening. The seamless passenger side inflatable restraint system also includes a side inflatable restraint module disposed within the instrument panel and aligned with the deployment opening. The seamless passenger side inflatable restraint system further includes a door reinforcement connected to the deployment door and operatively connected to the instrument panel to rotate the deployment door and retain the deployment door to the instrument panel after inflation of an air bag of the side inflatable restraint module.

Abstract: A method for forming an automotive instrument panel having a concealed door comprising a series of steps. A plastic parison is extruded to form the substrate layer of the instrument panel. The parison has first and second walls. The parison is placed within a mold and the first wall is contacted with the second wall to form a hinge. The area of contact forms a bond between the first and second walls. A different portion of the first and second walls are contacted to form an opening path. The opening path intersects the hinge. The opening path usually has a thickness much less than the thickness of the first and second walls to form an easily fracturable area. The door swings on the hinge to open. A elongated section of material on the second wall, enables the second wall to wrap along the hinge when the door is opened.

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 first 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 first surface of 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 an automotive instrument panel that conceals an airbag. The steps of manufacturing the instrument panel include providing a molded substrate having first and second surfaces and an aperture therethough, and a metal door having a generally U-shaped slot secured to the second surface of the substrate with a plurality of attaching posts. The slot has first and second ends being spaced apart a distance greater than the length of the aperture. The slot defines a flap in the door. The flap has a width greater than the width of the aperture. The door and substrate assembly is placed within a mold tool and a pre-molded covering is juxtaposed the substrate. A quantity of foam is injected between the substrate and covering and secures the covering to the substrate.