Method to create invisible air bag deployment panel

• US 6,692,019 B2
• Filed: 03/13/2001
• Issued: 02/17/2004
• Est. Priority Date: 03/13/2001
• Status: Expired due to Term

• Current Assignee: Inteva Products LLC (Renco Group Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Sommer, James John
• Primary Examiner(s): Dickson, Paul N.
• Assistant Examiner(s): Fleming, Faye M.
• Application Number:
  US09/805,491
• Publication Number:
  US 20020130497A1
• Time in Patent Office: 1,071 Days
• Field of Search: 280/732, 280/728.3, 280/743.1, 280/728.1, 428/43, 428/217
• US Class Current: 280/732
• CPC Class Codes: B26D 7/086 by vibrating, e.g. ultrasonically
• CPC Class Codes: B60R 21/205 in dashboards
• CPC Class Codes: B60R 21/2165 characterised by a tear line for defining a deployment opening

Abstract

A dash panel structure and method for forming such structure having an outer skin layer overlying a layer of foam cushioning material with a dimensionally stable support panel disposed below the foam cushioning material. A break-out pattern is applied across the surface of the substrate panel and into the overlying foam cushioning material in a pattern substantially corresponding to the desired deployment path of an underlying air bag cushion. The break-out pattern formed across the substrate panel is substantially aligned with a corresponding deployment opening pattern of grooved construction extending across the inner surface of the skin layer such that the deployment of the air bag cushion may be carried out at a controlled defined location within the dash panel structure.

Claims

1. A method for forming an air bag deployment opening at a location within a vehicle dash panel structure overlying an inflatable air bag cushion such that the location of the deployment opening is substantially hidden from the view of an occupant viewing the exterior of the dash panel structure, wherein the dash panel structure comprises an outer skin layer having an outer show surface forming the exterior of the dash panel structure and an interior surface facing away from the outer show surface, the dash panel structure further comprising an underlying support structure including a layer of foam disposed beneath the interior surface of the outer skin layer and a substrate panel disposed beneath the foam intermediate the interior surface of the outer skin layer and the inflatable air bag cushion, the method comprising the steps of:

applying a deployment opening pattern of grooved construction across the interior surface of the outer skin layer;

joining the outer skin layer to the underlying support structure such that the interior surface of the outer skin layer is disposed in substantially opposing relation to the underlying support structure; and

removing at least a portion of the material forming the underlying support structure in a pattern of slots extending through the substrate panel and at least partially into the foam, wherein the pattern of slots is substantially aligned with the deployment opening pattern across the interior surface of the outer skin layer such that upon inflation of the air bag cushion the dash panel structure is opened through the outer skin layer and the underlying support structure in a pattern substantially corresponding to the deployment opening pattern across the interior surface of the outer skin layer and wherein the deployment opening pattern across the interior surface comprises at least one elongate groove segment having a length greater than the slots extending through the substrate panel aligned with said at least one elongate groove segment.

2. The invention according to claim 1, wherein the substrate panel comprises a substantially rigid plastic material.

3. The invention according to claim 1, wherein the step of applying a deployment opening pattern of grooved construction across the interior surface of the outer skin layer is conducted such that a substantially uniform thickness of material is retained within the outer akin layer in overlying relation to the deployment opening pattern.

4. The invention according to claim 3, wherein the step of applying a deployment opening pattern of grooved construction across the interior surface of the outer skin layer is performed concurrently with the step of removing at least a portion of the material forming the underlying support structure in a pattern of slots extending through the substrate panel.

5. The invention according to claim 4, wherein a vibrating element is used to concurrently apply the deployment opening pattern of grooved construction across the interior surface of the outer skin layer and to remove material forming the underlying support structure in a pattern substantially aligned with the deployment opening pattern.

6. The invention According to claim 5, wherein the vibrating element is adjustable to various angles such that the vibrating element maybe swept in a substantially fanning action across the interior surface of to outer skin layer and through the material forming the underlying support structure so as to form a substantially continuous deployment opening pattern of grooved construction extending across the interior surface of the outer skin layer in substantial alignment with the pattern of slots within the substrate panel.