Abstract: The combination of a multi-layer instrument panel having a skin layer with an exposed surface and an opening therethrough and a first accessory that is mounted in the opening. The first accessory has an exposed surface that is substantially flush with the exposed surface of the skin layer with the first accessory mounted in the opening and operatively connected to the multi-layer instrument panel. The invention is also directed to a method of manufacturing the instrument panel with the first accessory.

Abstract: An air bag cover assembly having a core layer, a cushioning layer, and a door. The core layer has an opening through which an air bag which the air bag cover assembly operatively overlies extends as the air bag is changed from an undeployed state into a deployed state. The skin layer has oppositely facing forward and rear surfaces and is situated forwardly of the core layer. The door is changeable between a closed state and an open state. In the closed state, the door covers the core layer opening. The door has a weakening portion which separates as an incident of the air bag changing from the undeployed state into to the deployed state. The door has a first hinge with a curved portion which flexes to allow at least a first part of the door to pivot from a first position to a second position as an incident of the air bag changing from the undeployed state into the displayed state and the door changing from the closed state into the open state.

Abstract: The combination of an air bag having an undeployed state and a deployed state, and an instrument panel. The instrument panel overlies the air bag with the air bag in the undeployed state. The instrument panel has a skin layer with oppositely facing front and rear surfaces, a foamed resin layer on the rear surface of the skin layer and having a thickness, a core layer having an opening bounded by an edge through which the air bag extends with the air bag in the deployed state, and a door at the opening. The door has a peripheral edge and is repositionable from a closed position into an open position as an incident of the air bag changing from the undeployed state into the deployed state. The skin layer has a break portion defined by a groove at which the skin layer ruptures as the air bag changes from the undeployed state into the deployed state. The groove has first and second spaced sides and a base between the first and second sides.

Abstract: The combination of a multi-layer instrument panel having a skin layer with an exposed surface and an opening therethrough and a first accessory that is mounted in the opening. The first accessory has an exposed surface that is substantially flush with the exposed surface of the skin layer with the first accessory mounted in the opening and operatively connected to the multi-layer instrument panel. The invention is also directed to a method of manufacturing the instrument panel with the first accessory.