INSTRUMENT PANEL WITH INTEGRAL HIDDEN DOOR COVER AND METHOD OF MANUFACTURE THEREOF

摘要

An instrument panel having a deployable cover for an airbag module, the instrument panel including: a substrate layer with a tear seam formed therein; a bi-laminate layer comprising a foam layer and an outer layer with a tear seam formed therein, the tear seam of the bi-laminate layer of being aligned with the tear seam of the substrate layer, wherein the substrate layer and the bi-laminate layer are secured to each other and wherein the tear seam of the substrate layer and the tear seam of the bi-laminate layer are each separately formed prior to the substrate layer and the bi-laminate layer being secured to each other.

主权项

1. A method of forming a hidden, integral airbag door in an instrument panel, the method comprising:
molding a substrate layer; molding a bi-laminate layer with an outer surface layer and an intermediary foam layer to the substrate layer after the substrate layer has been molded; removing the bi-laminate layer from the substrate layer; scoring a tear seam in the bi-laminate layer; separately scoring a tear seam in the substrate layer; aligning the tear seam of the bi-laminate layer with the tear seam of the substrate layer; and securing the bi-laminate layer to the substrate layer.