Davidson Textron Inc.

David Textron, Inc.

Thomas G Parker

Peter J Iannazzi

Lawrence R Nichols

John D Gray

Robert Cooper

Lee E Gridley

Peter Ianazzi

A cover for an air bag unit is disclosed having a patterned tear seam therein defined by a partially bonded material same as the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with a narrow gap therein conforming to the desired tear seam pattern. The cover while in the shell mold is coated along the margins of the gap with a plastic parting agent and then more of the same or similar thermoplastic material is deposited in the gap and over the parting agent to form a partially bonded thermoplastic tear seam.

Air bag cover with seamless interface tear seam and method and apparatus

A closure for an air bag assembly includes a flexible outer skin and a layer of foam material covering a retainer member that has an air bag deployment opening that is closed by a moveable door. The door overlaps portions of the retainer member to support the door against movement inwardly of the retainer member and allow free hinging movement outwardly of the retainer member for stressing and separating the layer of foam and the outer skin to form a deployment path for the air bag. The moveable door may be retained in the closed position by frangible portions of the retainer member to facilitate manufacture of the closure.

Closure for an air bag assembly

A cover for an air bag unit is disclosed having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and comprising a material having properties different than that of the cover material, Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon, A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that have the tear seam pattern, The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Airbag cover and apparatus for producing an invisible tear seam therein

A cover for an air bag unit having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and including a material having properties different than that of the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that has the tear seam pattern. The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Method for forming an outer skin for a cover assembly

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.

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.

Trim panel having integral door cover

A laminated instrument panel has a door cover for concealing a supplemental inflatable restraint (SIR) system in a vehicle passenger compartment that includes a skin flap that is an integral part of the skin of the instrument panel. The skin flap is cast out of position and collapsed into the correct position when an elastomeric foam layer is foamed in place beneath the cast skin. This forms slanted grooves in the skin at the juncture of the flap and the adjacent skin of the instrument panel that have little or no gap at the surface of the skin. The skin flap can be shaped to provide a flush door or a raised door with an overlapping front edge.

Trim panel having integral SIR door cover

A cover normally concealing a safety air bag is adapted to rupture to form an opening for air bag deployment into the passenger compartment of a motor vehicle. The cover is formed of plastic material that tends to become embrittled and fragment when torn or pierced below a certain ambient temperature. A heater is provided behind the cover that is adapted to heat the rupture area in the event of air bag deployment. A heater control operates the heater to maintain this critical area above the fragmentation temperature when the vehicle is being operated at low ambient temperatures that would cause plastic embrittlement.

Preheated safety air bag cover

A self piercing cover assembly for concealing an air bag restraint system in a vehicle passenger compartment has a retractable cutter blade that is attached to the underside of an instrument panel next to front end of an invisible door beneath the instrument panel. When the air bag inflates, the cutter blade is pushed up by a deflector shield against the bias of springs and cuts through the instrument panel at several locations making it easier for the door to swing open. The deflector shield is then bent and broken off or deformed by the inflating air bag to provide a shield for protecting against contact with the sharp edges of the cutter blade. The shield and cutter blade retract under the action of the springs so that the shielded cutting edge is below the surface of the instrument panel to provide primary protection against contact with the sharp edges of the cutter blade after the air bag collapses.

Self piercing cover assembly for air bag having deformable deflector

A cover for an air bag unit is disclosed having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and comprising a material having properties different than that of the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that have the tear seam pattern. The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

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Strafford, NH, United States of America

Thomas G Parker