Abstract: According to the present invention, an instrument panel cover for use in an instrument panel of a vehicle compartment having a supplemental inflatable restraint (SIR) system and a method for manufacturing the instrument panel cover are provided. The instrument panel cover includes a body having an inner surface and an opposing outer surface, the body having an air bag cushion deployment region formed in the inner surface thereof, the deployment region being defined by at least one score formed in the inner surface to a predetermined depth, wherein the at least one score is formed by at least one scoring member which contacts the instrument panel cover during the manufacture thereof and the advancement of the at least one scoring member causes the instrument panel cover to thin out in predetermined locations which define the at least one score.

Abstract: The practice of joining two thermoplastic resin bodies with widely disparate melting temperatures is enhanced by providing a shallow, roughened surface on at least the higher melting point body. When the parts are clamped together for frictional engagement, the roughened surface increases the local pressure, accelerates the formation of a molten film between the bodies and provides a strengthening mechanical interlock in the welded joint.

Abstract: A vehicle lamp assembly has an opaque housing portion and a light transmissive lens portion. The housing includes a peripheral channel for accepting a sealing adhesive and a complementary peripheral tongue on the lens portion. The bottom of the channel is characterized by a plurality of energy directors which contact the tongue and are locally upset by a ultrasonic weld apparatus to provide local welding between the lens and housing. The local welding provides fixtureless retention of the respective parts during the curing of the sealing adhesive.