Toyo Tire Rubber Co., Ltd.

Yasushi Kawakubo

Shiro Ozaki

Takeshi Yamaji

Kazuhiko Yoshioka

Masahiko Yanagihara

An instrument panel for an air bag device has a surface member having a first surface component and a second surface component each with backsides. A foamed member is formed on the back sides of the surface member and cleavable by expanding pressure of an air bag of the air bag device where the air bag device is disposed adjacent the foam member. The first surface component and the second surface component respectively having first and second side edge portions with respective first and second engaging portions engaging one another to form an adjoining portion of the surface member whereat the surface member is cleaved by the expanding pressure of the air bag. The first engaging portion included a fitting groove having a generally U-shaped section extending from the backside of the first surface component into the foamed member. The second engaging portion includes a fitting protrusion extending from the backside of the second surface component and adapted to be inserted into the fitting groove. The foamed member is foamed onto the backside of the surface member with the fitting protrusion inserted into the fitting groove such that the fitting groove with the fitting protrusion inserted therein is embedded in the foamed member.

Instrument panel for air bag device, and process for manufacturing the same

Instrument panel for air bag

A method of fabricating an instrument panel includes providing a skin which forms a surface of the instrument panel and has side face portions extending rearwardly from a front face portion and providing a panel core having a recess for defining a molding space between the panel core and the skin. The front face portion and the side face portions define a bend angle. The recess of the panel core has peripheral walls for engaging the side face portions and the peripheral walls and a surface of the recess define a regular angle which is less than the bend angle. The bend angle, for instance, is larger than the regular angle by 2.degree. to 8.degree., and preferably by 3.degree. to 5.degree.. The panel core is placed in a first die and the skin is place in a second die such that the side face portions are deflected to fit into the recess of the panel core during mold closing. The dies are closed and a foaming material is injected between the panel core and the skin to integrate the panel core and the skin. The side face portions resiliently engage the peripheral walls to prevent leakage of the foaming material. In an embodiment of the method, a skin holding member is movably provided in the second die for holding the side face portions in position during mold closing. The skin holding member is withdrawn to permit engagement of the side face portions with the peripheral walls after mold closing.

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Osaka, Japan

Yasushi Kawakubo