Abstract: A molded motor vehicle instrument panel made of a thermoplastic material has an integral air bag deployment door for a passenger side air bag that is defined by a tear seam and is normally retained by an integral flexible mounting/hinge flange to a part of the vehicle structure when the seam is torn by the inflating air bag and wherein this flange then bends to allow the door to swing open to allow deployment of the air bag through an opening in the instrument panel while retaining same to the vehicle structure as the door is then free of the instrument panel. At very low temperatures, a portion of the air bag door can break away from the mounting/hinge flange because of plastic embrittlement at these low temperatures and the high bending stresses encountered at this juncture.

Abstract: A molded motor vehicle instrument panel made of a thermoplastic material has an integral air bag deployment door for a passenger side air bag that is defined by a tear seam and is normally retained by an integral flexible mounting/hinge flange to a part of the vehicle structure when the seam is torn by the inflating air bag and wherein this flange then bends to allow the door to swing open to allow deployment of the air bag through an opening in the instrument panel while retaining same to the vehicle structure as the door is then free of the instrument panel. At very low temperatures, a portion of the air bag door can break away from the mounting/hinge flange because of plastic embrittlement at these low temperatures and the high bending stresses encountered at this juncture.

Abstract: An automotive instrument panel includes a molded plastic retainer formed with an integral airbag deployment door surrounded by a channel defining a tear seam enabling the door to separate and hinge outwardly upon deployment of the airbag. A foam-backed cover of flexible plastic material is applied over the outer surface of the panel and is severed along the length of the channel to eliminate any influence that the cover may have on resisting the opening of the door. The severed cover portion can either be removed to expose the door or else be left in tact and bonded to the door.

Abstract: A molded motor vehicle instrument panel made of a thermoplastic material has an integral air bag deployment door for a passenger side air bag that is defined by a tear seam and is normally retained by an integral flexible mounting/hinge flange to a part of the vehicle structure when the seam is torn by the inflating air bag and wherein this flange then bends to allow the door to swing open to allow deployment of the air bag through an opening in the instrument panel while retaining same to the vehicle structure as the door is then free of the instrument panel. At very low temperatures, a portion of the air bag door can break away from the mounting/hinge flange because of plastic embrittlement at these low temperatures and the high bending stresses encountered at this juncture.

Abstract: A molded motor vehicle instrument panel made of a thermoplastic material has an integral air bag deployment door for a passenger side air bag that is defined by a tear seam and is normally retained by an integral flexible mounting/hinge flange to a part of the vehicle structure when the seam is torn by the inflating air bag and wherein this flange then bends to allow the door to swing open to allow deployment of the air bag through an opening in the instrument panel while retaining same to the vehicle structure as the door is then free of the instrument panel. At very low temperatures, a portion of the air bag door can break away from the mounting/hinge flange because of plastic embrittlement at these low temperatures and the high bending stresses encountered at this juncture.

Abstract: A method is disclosed for forming a reinforced plastic skin for an automobile interior trim structure. The method includes the steps of supplying a plastic material onto a mold surface, heating the plastic material to fuse it into a unitary layer, embedding a reinforcing material into the layer, and cooling the plastic and reinforcing materials. The method can be used to reinforce an air bag door cover by incorporating a tear seam into the plastic layer and embedding the reinforcing material into the layer such that it surrounds the tear seam. The reinforcing material aids in rupturing of the cover along the designated tear seam during deployment of the air bag. Also disclosed is an air bag door cover formed in accordance with the disclosed method.

Abstract: An air bag restraint system is housed within an interior trim product with a hidden door that is opened when an air bag is inflated for deployment into the passenger car or a vehicle. The door is formed in a reinforced segment of a layer of low density rigid foam material that forms the load bearing support for the interior trim product and a backing for an outer skin or decorative surface that forms the outer cover of the interior trim product. The hidden door is formed by cast in place segments in the reinforced segment of the layer of low density rigid foam material a door hinge segment and a weakened tear seam segment which separates when the air bag impacts thereagainst to tear the outer skin for forming an opening therethrough for deployment of the air bag into the passenger compartment of a vehicle.

Abstract: A closure for an air bag assembly includes a flexible outer skin and a layer of foam material covering a retainer member having an air bag deployment opening therein closed by a moveable door that is overlapped with the retainer member to support the door against movement inwardly of the retainer member while providing free hinging movement thereof with respect to the retainer member for stressing and separating the layer of foam and the outer skin for forming a deployment path therethrough for the air bag.

Abstract: An instrument panel has an integral door cover for concealing a supplemental inflatable restraint system in a vehicle passenger compartment. The door cover includes a flap that is an integral part of a flexible plastic skin of the instrument panel. The plastic skin is cast in a special mold with a raised apexed rib that forms grooves outlining the flap that have a thin tear seam at their bottom.

Abstract: A method is disclosed for forming a reinforced plastic skin for an automobile interior trim structure. The method includes the steps of supplying a plastic material onto a mold surface, heating the plastic material to fuse it into a unitary layer, embedding a reinforcing material into the layer, and cooling the plastic and reinforcing materials. The method can be used to reinforce an air bag door cover by incorporating a tear seam into the plastic layer and embedding the reinforcing material into the layer such that it surrounds the tear seam. The reinforcing material aids in rupturing of the cover along the designated tear seam during deployment of the air bag. Also disclosed is an air bag door cover formed in accordance with the disclosed method.

Abstract: An instrument panel has an integral door cover for concealing a supplemental inflatable restraint system in a vehicle passenger compartment. The door cover includes a flap that is an integral part of a flexible plastic skin of the instrument panel. The plastic skin is cast in a special mold with a raised apexed rib that forms grooves outlining the flap that have a thin tear seam at their bottom.