Abstract: A method of making a thermoplastic skin comprises the steps of providing a mold having a mold surface with first and second mold surface portions which intersect at a sharp corner coincident with the desired location of the tear seam in the molded skin. The mold is oriented with one of the first and second mold surface portions oriented in a generally horizontally orientation and the other of the mold surface portions oriented in a generally vertical orientation. A thermoplastic material such as polyurethane is sprayed onto the mold surface and the curing of the sprayed material is controlled to permit gravity to induce flow of the sprayed material down the vertical surface of the mold at the sharp corner and thereby provide a cured skin which is of significantly lessened thickness at the corner than at other regions of the skin.

Abstract: A dual stage air bag suppression system based upon seat position. A deceleration sensor senses the deceleration of the vehicle during a crash/collision. If the deceleration exceeds a first threshold value, and the seat is rearward of a predetermined value, then the SIR Controller initiates a first/low stage inflation. If the deceleration exceeds a second higher threshold value, and the seat is rearward of a predetermined value, then the SIR Controller initiates both first/low and second/high stages of inflation. If the seat is positioned at a point forward of a predetermined position, then the SIR Controller initiates the first/low stage inflation only when the deceleration exceeds the first/lower or second/higher threshold value and suppresses deployment of the second stage. Thus the SIR Controller initiates the inflation stages not only based on the severity of the collision or deceleration, but also based on the position of the vehicle seat.

Abstract: A disabling system is provided for a supplemental inflatable restraint system in a vehicle. The disabling system includes a seat movable forward and rearward in the vehicle. The seat has a predetermined seat position. The disabling system automatically disables the supplemental inflatable restraint system when the seat is moved forward of the predetermined seat position and automatically enables the supplemental inflatable restraint system when the seat is moved rearward of the predetermined seat position. In a preferred form of the invention, the predetermined seat position occurs when the seat is fully forward in the vehicle such that the supplemental inflatable restraint system is automatically disabled when the seat is at the fully forward position.

Abstract: An air bag module is mounted on the instrument panel structure forwardly of the passenger seating position and has an air bag normally stored and folded therein and inflatable to project into the occupant compartment to restrain the passenger. An instrument panel cover is mounted atop the instrument panel structure to conceal the air bag from view and extends transversely across the instrument panel structure forwardly of both the driver and passenger sides of the occupant compartment. The instrument panel cover has a weakened tear seam which originates at the rearward most edge of the cover, at a point between the driver and the passenger and proceeds from the rearward edge in a generally forward direction. The driver side portion of the instrument panel cover is fixedly fastened to the instrument panel structure. The passenger side portion of the instrument panel cover is detachably fastened to the instrument panel cover.