Patent ID: 6692019
Filing Date: 2004-02-17
Classification: B26D,B60R

Abstract:
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.