Morton International, Inc.

W Gary Wirt

Patrick G Jarboe

Donald R Lauritzen

Gregory J Lang

Bradley D Harris

Russell S Gans

Jeffery L Scharret

A flexible sensor, such as a membrane switch, is molded into a plastic automotive panel by a low temperature, low pressure, method which avoids damage to the switch while insuring its placement at a desired depth below the surface of the panel. This is achieved by a process which includes a first step of spraying a mold with a rapid gelling liquid plastic to a preselected thickness. After the plastic has firmed, the sensor is placed thereon and is encapsulated by spraying with a second layer of the plastic. The resulting shell with the embedded sensor may then be provided with a backing, such as a plastic foam.

Method of encapsulating a sensor into a panel body

An invisible cover door for an inflatable passive passenger restraint is provided in an interior trim structure of an automotive vehicle for deployment of an airbag therethrough. The low pressure insert injection molding of the cover door into the interior trim structure, such as an instrument panel or dashboard or door panel structure, produces an invisible cover door with tear propagation lines that are undetectable to a vehicle occupant and that do not 'show' or mar or otherwise affect the aesthetic appearance of the outer trim surface of the instrument panel or dashboard. Such invisible doors which require only two tear propagation lines can be provided.

Method of making an invisible instrument panel or dashboard airbag cover

Invisible instrument panel or dashboard airbag cover door

A tethered cover airbag system is provided for motor vehicles and the like having a panel formed with an opening in the vicinity of an occupant's seat and including an inflatable airbag mounted in a housing or canister for containing the bag in a deflated condition. The housing has an open end aligned with a panel opening to permit the airbag to pass outwardly when deployed for cushioning support for an occupant in the adjacent seat. A cover is provided for normally closing the panel opening to protect the airbag and is bodily movable to uncover the opening during airbag deployment. A flexible tether is interconnected between the cover and the panel edge or the housing for limiting the movement of the cover away from the panel during deployment. A suitable attachment system is provided for spreading the load exerted by the tether over a large area of the cover for reducing stress exerted on the cover during airbag deployment. The tether thus restrains the cover from moving around the passenger compartment of the vehicle in an uncontrolled manner during an airbag deployment and by reducing the load or stress exerted on the cover by the tether, the chance of break-up or fracturing of the cover into pieces is minimized.

Airbag system with tethered cover

Growing community of inventors

Clinton Township, MI, United States of America

W Gary Wirt