Textron Automotive Company Inc.

Davidson Textron Inc.

Collins & Aikman Products & Co.

Craig B Labrie

John D Gray

Bruce A Batchelder

Michael J Gallagher

Richard D Rhodes, Jr

Claude E Bemis

Jimmy C Rogers

Marie J Hersman

Vernon A Daniels

Edwin V Stawicki

David R McCooey

Nelson J Morren

John J Kennedy

Norman J Clavette

Gordon Warren

Jack J Kennedy

Robert J Dadura

An apparatus for deploying an air bag through an automotive dash panel () includes an air bag door () integrally formed in the panel and defined by a door perimeter including a frangible edge () of reduced cross section. A dispenser () supports the air bag () behind the door. A metal reaction plate () is positioned between the air bag () and the door (). When the air bag inflates, it forces the reaction plate () to bend around a horizontal hinge line (). As the reaction, plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers () limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending. After deployment, the reaction plate remains in a position that prevents the door from returning to its original position. A retaining structure may be included to preclude at least a portion of the air bag door from tearing free of the vehicle panel. A hinge () may be embedded in the panel in a position spanning a portion of the door perimeter. A hollow channel may be formed into the panel along the frangible marginal edge to create a substantial strength differential with the door perimeter to promote bending along the hinge and/or to help confine tearing to the frangible marginal edge during air bag deployment.

Apparatus for deploying an air bag through a hard panel

An air bag cover assembly is provided comprising a retainer panel having an aperture during the deployment of an inflatable air bag for the airbag to pass through. The aperture has a cross-sectional area during air bag inflation greater than the cross-sectional area of the aperture when the air bag is deflated after being inflated. A method of providing an air bag deployment aperture for an air bag cover assembly is also provided. The method comprises providing a retainer panel, forming an aperture in the retainer panel for the deployment of an inflating air bag from an air bag module, increasing the cross-sectional area of the aperture during inflation of the air bag, and decreasing the cross-sectional area of the aperture after the air bag has at least partially passed through the aperture.

Air bag cover assembly

An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in to 35 in , and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.

Inflatable restraint apparatus

An inflatable restraint deployment system includes a simplified hold-down assembly for fastening an air bag door in a tamper-proof closed position. The deployment system includes an air bag door pivotally supported adjacent an air bag deployment opening in an automobile dashboard and two fasteners that releasably secure the door in a closed position over the air bag deployment opening. The fasteners each include an elongated shaft portion that either extends integrally upward from an air bag canister flange or integrally downward from an air bag door substrate. The fasteners are aligned in the direction of door movement. Each fastener shaft portion extends through one of a pair of fastener holes formed either in the air bag door substrate or in the canister flange. A fastener flange extends outward from around the shaft portion of each fastener and engages a rim that defines one of the fastener holes. Each fastener hole defines an area slightly smaller than the cross-sectional area of the thickest portion of each fastener flange. Either the fastener hole rims or the fastener flanges yield when air bag inflation forces the air bag door to pivot out of the closed position.

Release assembly and method for deploying a supplemental restraint system

An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in to 35 in , and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag having a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.

An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a door perimeter including a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates, it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending. After deployment, the reaction plate remains in a position that prevents the door from returning to its original position. A retaining structure may be included to preclude at least a portion of the air bag door from tearing free of the vehicle panel. A hinge may be embedded in the panel in a position spanning a portion of the door perimeter. A hollow channel may be formed into the panel along the frangible marginal edge to create a substantial strength differential with the door perimeter to promote bending along the hinge and/or to help confine tearing to the frangible marginal edge during air bag deployment.

Apparatus for deploying an airbag through a hard panel

An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending. After deployment, the reaction plate remains in a position that prevents the door from returning to its original position.

A vehicle interior trim component, such as a glove compartment or console door, and its method of fabrication includes an outer flexible shell having a peripheral contoured return flap captured within a peripheral gap provided between insert and backing panels of the component. Foam is injected into a space between the outer shell and insert panel and any gases and excess foam are allowed to escape from the foam space into an adjacent overflow chamber in a controlled manner through the gap while the return flap seals the assembly against external leakage of such excess foam.

Method of fabricating a foamed interior trim product

A method for fabricating plastic interior trim components having an insert with openings therein joined to a composite member including a shell and a foam layer, the method including die punching a hole through the shell and foam layer and die punching an edge extension on the shell to a predetermined parametric form; providing a press that is operable to compress a part therebetween and including a first platen and a second platen moveable between opened and closed positions with respect to one another; providing an insert having an opening; supporting the insert on one of said first and second platens and applying adhesive on a surface of the insert; loading the composite member on the other of said first and second platens so that the foam layer thereof is facing the adhesive sprayed insert inboard of the die cut edge extension; closing the press to compress the adhesive sprayed surface against the foam layer of the composite member for adhering the insert only to the foam layer without leakage of foam through openings in the insert.

Method for fabricating vinyl covered foamed parts

A door cover assembly for concealing a supplemental inflatable restraint (SIR) system of an automotive interior trim component includes a substrate having a door section in which formed depressions are provided to strengthen the door. The depressed regions are filled with a secondary foam insert to level the outer surface of the substrate. A primary foam layer overlies the substrate and is covered by an outer vinyl shell. The leveling of the substrate by the secondary foam insert eliminates 'show through' of the depressed regions on the outer Class A surface of the vinyl shell.

Construction and method of forming a door assembly for an air system

A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance. The door is formed by a process that includes the steps of providing a composite plastic structure having a molded shell and foam component with an insert located in spaced relationship with respect to the shell to define a foamed cavity with a raw edge of foam and shell around the periphery of the composite member; providing a post formed flange on the insert and loading the shell, foam and insert components into a female nest; and heat die post forming of the flange to upset it into net out overlaying relationship with both the raw edge of the shell and the exposed edge of foam formed in the composite part so as to produce a finished exterior surface on the composite part.

Interior trim foam product and method of fabrication thereof

A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance. The door is formed by a process that includes the steps of providing a composite plastic structure having a molded shell and foam component with an insert located in spaced relationship with respect to the shell to define a foamed cavity with a raw edge of foam and shell around the periphery of the composite member; providing a post formed flange on the insert and loading the shell, foam and insert components into a female nest; and heat die post forming of the flange to upset it into net out overlying relationship with both the raw edge of the shell and the exposed edge of foam formed in the composite part so as to produce a finished exterior surface on the composite part.

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Dover, NH, United States of America

Craig B Labrie