Patent ID: 6070901
Filing Date: 2000-06-06
Classification: B60R

Abstract:
A method of manufacturing an automotive instrument panel having a concealed airbag comprising the steps of:molding a substrate to having first and second surfaces;providing a metal door having a peripheral portion and a slot that defines a door, this door being one of U-shaped, H-shaped, or oval shaped, a generally U-shaped slot with first and second ends defining a foldable flap, the line between said first and second ends defining a folding axis for said flap;securing said door to said first substrate surface;positioning a covering over said door and said substrate;injecting a foam between said substrate and said covering to secure said covering to said substrate and said door;imaging said substrate second surface in the area overlying said slot with a high intensity light beam and causing said light beam to completely penetrate said substrate and foam and to partially penetrate said covering, said light beam passing through said slot in said metal door and causing said substrate, foam and covering to form a fracturable opening path;imaging said substrate second surface in the area overlying said folding axis with a high intensity light beam and causing said light beam to completely penetrate said substrate and contact said door, said light beam severing a section of said substrate;removing said severed section of substrate to form an aperture through said substrate for an airbag; andsecuring an airbag behind said aperture, said airbag having sufficient force to fracture said opening path and fold said door when activated.