Abstract: A method of manufacturing a chute panel of an airbag assembly. The method comprises forming a substrate from a material with the substrate comprising a plurality of projections projecting from a first surface of the substrate. A living hinge including a plurality of apertures is secured to the substrate with at least portion of the apertures mating with a portion of the projections of the substrate to secure the hinge to the substrate. A chute door is formed onto the substrate and onto the hinge secured to the substrate. A chute is formed onto the substrate with a portion of the chute interacting with a portion of the plurality of projections of the substrate, thereby forming a chute panel of an airbag assembly.

Abstract: A method of manufacturing a chute panel of an airbag assembly. The method comprises forming a substrate from a first material to have a body having first and second ends and a longitudinal axis extending therebetween and a void residing in the body. The method further comprises forming a chute and a chute door from a second material. The chute comprises a base molded onto the substrate body and one or more sidewalls extending from the base. And wherein forming the chute door comprises filling the void in the substrate body with the second material to form the chute door.

Abstract: A method of manufacturing a chute panel of an airbag assembly. The method comprises forming a substrate from a first material to have a body having first and second ends and a longitudinal axis extending therebetween and a void residing in the body. The method further comprises forming a chute and a chute door from a second material. The chute comprises a base molded onto the substrate body and one or more sidewalls extending from the base. And wherein forming the chute door comprises filling the void in the substrate body with the second material to form the chute door.

Abstract: Some embodiments are directed to an assembly for housing and covering a vehicle airbag in an un-deployed state. The assembly can include a hollow housing that defines an interior that is configured to house the airbag in the un-deployed state. The housing can include a door having a linearly extending primary weakened portion spanning longitudinally opposing ends of the housing. The housing door can also include a pair of angled seams that each extend proximate the primary weakened portion to a location adjacent opposing corners of the door. The assembly can also include an intermediate layer disposed over and joined to the housing door, and an exterior layer disposed over and joined to the intermediate layer.

Abstract: Some embodiments are directed to an assembly for housing and covering a vehicle airbag in an un-deployed state. The assembly can include a hollow housing that defines an interior that is configured to house the airbag in the un-deployed state. The housing can include a door having a linearly extending primary weakened portion spanning longitudinally opposing ends of the housing. The housing door can also include a pair of angled seams that each extend proximate the primary weakened portion to a location adjacent opposing corners of the door. The assembly can also include an intermediate layer disposed over and joined to the housing door, and an exterior layer disposed over and joined to the intermediate layer.