Patent Description:
Airbag devices are a common safety feature in most vehicles. The airbag devices are located in regions of the vehicle that are likely to be contacted by an occupant in the event of a collision. The airbag devices deploy when the vehicle senses that a collision has taken place causing an airbag to fill with gas so that it expands into an expanded configuration to cushion the impact of an occupant against regions of the vehicle interior.

The airbag devices may be located in front of the occupants, such as in the steering wheel, instrument panel, facia panel located in front of a non-driving seat, and side columns of the vehicle. In each case, these protect the occupant from particular collision situations.

In high performance vehicles and/or vehicles that are at least partially battery powered, it is desirable to attempt to keep the overall weight of the vehicle as low as possible. In the case of high-performance vehicles, this is so that handling and acceleration can be improved. In the case of vehicles that are at least partially battery powered, this can increase the range of the vehicles.

The use of composite materials in a vehicle is one method of reducing the total weight of the vehicle. Composite materials may be used to manufacture components of the vehicle. For instance, they can be used to form external body panels of the vehicle. Composite materials can also be used to form internal panels such as those that form parts of the facia or side columns of the vehicle. The composite material may be fibre-reinforced composite (FRC) materials. Such materials typically comprise a matrix that contains reinforcing fibres. As an example, the matrix could be an epoxy resin and the fibres could be carbon fibre (CF) strands. Materials of this type can have good strength in comparison to their weight. One example method by which FRC materials can be formed is resin transfer moulding. Another process for forming FRC materials uses reinforcing fibres that are pre-impregnated with a matrix material such as resin.

These are generally known as pre-preg. These reinforcing fibres can be laid up in a mould cavity and then the pre-impregnated matrix material can be cured, typically by heating the mould body. The heating may take place in an autoclave. Once the resin has become solid the mould can be opened and the resulting component removed.

Panels that are formed of composite materials that overlay an airbag device typically have a cut out in the panel through which the airbag device deploys its airbag. A filler panel is inserted in the cut out to fill the hole during normal use of the vehicle. It can be difficult to seal this filler panel to the surrounding panel in a manner that means it is both releasable in the event of a collision but is secured sufficiently that it does not cause unwanted noises or sealed sufficiently that material cannot pass through the join between the filler panel and the surround. In addition, the direction of the fibres in a composite material are important for the strength of the panel. It can be difficult to obtain high levels of alignment between fibres in two different pieces. This can effect the strength and also visual appearance of the panels.

It would therefore be desirable for there to be an improved way of using panels formed of composite materials as a cover for an airbag device.

The document <CIT> representing the closest prior art discloses a vehicle comprising: an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through an aperture in the housing when moving from the packed configuration to the expanded configuration;a composite material panel positioned to cover the airbag device, the pane comprising a break line running over the panel, the break line being proximal to the aperture so that when the airbag moves to the expanded configuration the airbag forces the panel to tear along the break line; and a first protection flap, the first protection flap having an initial configuration where the first protection flap is located adjacent the airbag in the packed configuration and a deployed configuration where the first protection flap covers at least one edge of the panel that runs along one side of the break line when the panel has torn due to the airbag moving to the expanded configuration.

According to a first aspect of the present invention there is provided a vehicle comprising: an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through the aperture in the housing when moving from the packed configuration to the expanded configuration; a composite material panel positioned to cover the airbag device, the panel comprising a break line running over the panel, a detachable portion within the break line and a fixed portion outside of the break line, the detachable portion becoming at least partially detached when the airbag forces the panel to tear along the break line, the break line being proximal to the aperture so that when the airbag moves to the expanded configuration the airbag forces the panel to tear along the break line; a first protection flap, the first protection flap having an initial configuration where the first protection flap is located adjacent the airbag in the packed configuration and a deployed configuration where the first protection flap covers at least one edge of the panel that runs along one side of the break line when the panel has torn due to the airbag moving to the expanded configuration; a tether attached between the detachable portion and the fixed portion; and a second protection flap, the second protection flap being attached to the detachable portion, the second protection flap being configured to cover at least one edge of the detachable portion once the detachable portion is at least partially detached.

The composite material panel may be formed of reinforcement material interspersed with matrix material. The reinforcement material may be carbon fibre. The composite material panel may be formed of fibre-reinforced polymer.

The aperture in the housing may be a chute through which the airbag expands when moving to the expanded configuration.

The break line may form a closed path running over the panel. The break line may be formed of perforations in the panel along the break line. The break line may be a groove in the panel. The groove may be formed in a surface of the panel facing the airbag device. The groove may be broken by full thickness portions of the panel. The groove may be formed by cutting the groove into the panel. The groove may be formed during a forming process for the panel by laying up reinforcement material with a gap to form the groove. The panel may be formed of a continuous layer of reinforcement material which forms a surface visible from within the vehicle, and layers of reinforcement material applied to the surface of the panel facing the airbag device with a gap to form the groove. The break line may be formed by a series of micro-drilled holes.

The second protection flap may be attached to the detachable portion at one end of the second protection flap. The tether may permit the detachable portion to move away from the airbag device prior to rotating about an axis defined by the tether. The airbag device may be positioned relative to the panel so that when the airbag moves to the expanded configuration the airbag forces the panel to tear starting from a portion of the break line remote from the tether. The second protection flap may move with the detachable portion as the detachable portion moves due to being forced by the airbag moving to the expanded configuration.

The vehicle may comprise an occupant cabin and the panel may form a visible surface of the occupant cabin. The vehicle may comprise an occupant cabin and the panel may form part of a facia of the occupant cabin. The vehicle may comprise an occupant cabin and the panel may form part of a pillar the occupant cabin. The airbag device may be a one of: front airbag device in the occupant cabin, a side airbag device in the occupant cabin, driver airbag device mounted in a steering wheel of the vehicle, a knee airbag in the occupant cabin, a head airbag in the occupant cabin, and a curtain airbag in a headlining of the occupant cabin.

According to a third aspect of the present invention there is provided a composite material panel for covering an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through the aperture in the housing when moving from the packed configuration to the expanded configuration, the composite material panel comprising a break line running over the panel, the break line being capable of tearing when the composite material panel is positioned so that the break line is proximal to the aperture and the airbag moves to the expanded configuration to force the panel to tear along the break line.

The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art.

The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

The present invention relates to a vehicle comprising an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through the aperture in the housing when moving from the packed configuration to the expanded configuration. The vehicle also comprises a composite material panel positioned to cover the airbag device, the panel comprising a break line running over the panel, the break line being proximal to the aperture so that when the airbag moves to the expanded configuration the airbag forces the panel to tear along the break line. The vehicle may also comprise a first protection flap, the first protection flap having an initial configuration where the first protection flap is located adjacent the airbag in the packed configuration and a deployed configuration where the first protection flap covers at least one edge of the panel that runs along one side of the break line when the panel has torn due to the airbag moving to the expanded configuration. The present invention also relates to a composite material panel for covering an airbag device comprising a housing and an airbag, the airbag having a packed configuration and an expanded configuration, the airbag expanding through the aperture in the housing when moving from the packed configuration to the expanded configuration. The composite material panel comprises a break line running over the panel, the break line being capable of tearing when the composite material panel is positioned so that the break line is proximal to the aperture and the airbag moves to the expanded configuration to force the panel to tear along the break line.

<FIG> shows a vehicle <NUM>. The vehicle <NUM> may be an automobile. The vehicle <NUM> may be a car. The vehicle <NUM> comprises front wheels <NUM> and rear wheels <NUM>. The front of the vehicle is defined with reference to the primary motion direction of the vehicle <NUM>. The front of the vehicle <NUM> points in the primary motion direction of the vehicle. Generally, a vehicle has a primary motion direction that is the forward direction. The vehicle <NUM> comprises an occupant compartment <NUM>. The occupant compartment <NUM> may comprises one or more seats <NUM> for occupants of the vehicle to sit in. Whilst two seats <NUM> are shown in <FIG> it will be appreciated that more may be included in the vehicle <NUM>. The occupant compartment <NUM> may accommodate a driver. The occupant compartment may accommodate one or more passengers. The vehicle <NUM> may comprise controls <NUM> located within the occupant compartment <NUM> to enable an occupant to control the motion of the vehicle. The occupant compartment <NUM> may also be known as a passenger compartment.

The vehicle comprises a vehicle body <NUM>. The vehicle body <NUM> may comprise one or more openings through which an occupant may enter or exit the vehicle <NUM> or items such as luggage may be introduced to or taken from the vehicle <NUM>. The vehicle <NUM> may comprise one or more doors <NUM> to close those openings. As pictured in <FIG>, the vehicle <NUM> comprises two doors <NUM>. It will be appreciated that the vehicle may comprise more or less doors <NUM> than this.

The vehicle <NUM> may comprise a roof. The roof may be fixed or it may be removable. The roof may be removable in that it can be stowed inside the vehicle or manually removed and stored elsewhere. The roof is not shown in <FIG> so that the occupant compartment <NUM> can be viewed. The occupant compartment <NUM> comprises an interior which forms the surfaces of the occupant compartment. The interior comprises a plurality of interior panels which form the occupant compartment <NUM>. For example, the interior panels may include front facia panels <NUM> which may also be known as instrument panels <NUM>, door panels <NUM>, and pillars <NUM>.

The vehicle <NUM> comprises at least one airbag device <NUM>. As pictured in <FIG>, the vehicle comprises four airbag devices <NUM>. Airbag devices <NUM> may be located in any suitable location which an occupant may come into contact with during the vehicle colliding with another object. As pictured in <FIG>, the vehicle <NUM> has airbags located in the front facia <NUM>, the steering wheel <NUM>, side pillars <NUM>, and door casing <NUM>. The vehicle may have airbag(s) located in the headlining of the occupant cabin.

<FIG> shows a close-up view of the instrument panel <NUM> of the vehicle <NUM> shown in <FIG>. The front facia <NUM> comprises a facia panel <NUM>. The facia panel <NUM> is a composite material panel. The composite material panel may be formed of reinforcement material interspersed with matrix material. In this way the composite material panel may be a fibre-reinforced composite material panel. The reinforcement material may be fibre reinforcement material. The reinforcement material may be carbon fibre. The composite material panel may be formed of fibre-reinforced polymer. The matrix material may be a resin, for instance epoxy.

The composite material panel <NUM> is positioned to cover the airbag device <NUM>. Thus, from the view of an occupant of the occupant compartment <NUM> the airbag device <NUM> is located behind the composite material panel <NUM>. The composite material panel <NUM> obscures the airbag device <NUM> so it cannot be seen from within the occupant compartment <NUM> during normal use of the vehicle <NUM>. It will be appreciated that if the airbag device <NUM> deploys then it will be visible within the occupant compartment <NUM> but this constitutes a deviation from normal use as the vehicle <NUM> will have likely been in a collision or other accident.

The composite material panel <NUM> comprises a break line <NUM>. The break line <NUM> runs over the panel <NUM>. The break line <NUM> shown in <FIG> forms a closed path running over the panel <NUM>. The break line <NUM> may a continuous line on the panel <NUM> over that closed path. The break line <NUM> may also be discontinuous but run along the closed path. The break line may also be a non-closed path shape. Examples are shown in <FIG>. As shown in <FIG>, the break line may run around three sides of the airbag device <NUM> as projected on to the panel <NUM>. The break line may be U-shaped. The break line may run around all but one side of the airbag device <NUM> as projected on to the panel <NUM>. As shown in <FIG>, the break line may run along two opposite sides of the airbag device <NUM> as projected on to the panel <NUM> with a line joining those two opposite sides. The line may join the middle of the lines running along the two opposite sides. The break line may be H-shaped. As shown in <FIG>, the break line may be formed of three divergent lines that meet at a point. The point may be central to the airbag device <NUM> as projected on to the panel <NUM>. The break line may be Y-shaped.

The break line <NUM> runs over the panel <NUM> in a way so that it is proximal to the airbag device <NUM>. The airbag device <NUM> can cause the panel <NUM> to tear along the break line <NUM> when the airbag device <NUM> deploys. The break line <NUM> introduces a weakness in the panel <NUM> so that the tearing of the panel <NUM> can be controlled to occur along the break line <NUM>. The panel <NUM> is therefore frangible along the break line <NUM>.

<FIG> are cut through views of the area of the vehicle <NUM> which contains the panel <NUM> and the airbag device <NUM>. <FIG> shows the airbag device <NUM> in an undeployed state. <FIG> shows the airbag device <NUM> in a deployed state.

Airbag device <NUM> comprises a housing <NUM>. The housing <NUM> is attached to the vehicle <NUM>. The housing <NUM> may be attached to a substructure of the occupant compartment <NUM> of the vehicle <NUM>. The airbag device <NUM> comprises an airbag <NUM>. The airbag <NUM> has a packed configuration, as shown in <FIG>. The airbag <NUM> has an expended configuration, as shown in <FIG>. In the packed configuration, the airbag <NUM> is located within the housing <NUM>. In the expanded configuration, the airbag <NUM> extends outside of the housing <NUM> to provide a cushion to an occupant located in the proximity of the airbag <NUM> during a vehicle collision. It will be appreciated that the airbag <NUM> may only be in the fullest expanded configuration for a brief period of time when it is fully inflated.

The housing <NUM> has an aperture <NUM> through which the airbag <NUM> expands when moving from the packed configuration to the expanded configuration. The aperture <NUM> may be known as the chute of the airbag device <NUM>. The aperture <NUM> may be known as the guide channel of the airbag device <NUM>. The aperture <NUM> provides a path for the airbag <NUM> to expand through when being inflated. The airbag device <NUM> comprises an inflator <NUM>. The inflator <NUM> is coupled to the airbag <NUM> to provide gas to the airbag <NUM> to cause it to inflate. The gas may be generated by a chemical reaction inside the inflator <NUM>. The inflation of the airbag <NUM> causes the airbag <NUM> to move from the packed configuration to the expanded configuration. The activation of the inflator <NUM> may be controlled by sensors in the vehicle <NUM> which detect a collision situation of the vehicle <NUM>. The packed configuration of the airbag <NUM> corresponds with the airbag device <NUM> being in a undeployed state. The expanded configuration of the airbag <NUM> corresponds with the airbag device <NUM> being in a deployed state.

As shown in <FIG>, the break line <NUM> runs over the panel <NUM> in a way so that it is proximal to the aperture <NUM> of the airbag device <NUM>. Therefore, when the airbag <NUM> moves from to the expanded configuration the airbag <NUM> forces the panel <NUM> to tear along the break line <NUM>. The break line <NUM> may run over the panel <NUM> so that the panel first starts to tear in a selected part of the break line <NUM>. This may be selected by positioning part of the break line <NUM> closer to the airbag <NUM> than other parts of the break line <NUM>. The airbag <NUM> may also be shaped so that the initial expansion of the airbag <NUM> causes pressure to be applied first to a selected region of the panel <NUM> which causes the break line <NUM>. However, usually the airbag <NUM> will be of a standard shape and the panel <NUM> position and break line <NUM> position will be selected to cause the required tearing. The break line <NUM> means that the panel <NUM> comprises a detachable portion <NUM> within the break line <NUM> and a fixed portion <NUM> outside of the break line <NUM>.

The detachable portion <NUM> may be the portion of the panel <NUM> which moves when the airbag <NUM> forces the panel <NUM> to tear along the break line <NUM>.

To ensure that the detachable portion <NUM> moves in a required and safe manner when being forced by the airbag <NUM>, the vehicle comprises a tether <NUM> attached between the detachable portion <NUM> and the fixed portion <NUM>. The tether <NUM> defines the motion path of the detachable portion <NUM> as the panel <NUM> is forced by the airbag <NUM>. The tether <NUM> comprises a first attachment region <NUM> to the detachable portion <NUM> and a second attachment region <NUM> to the fixed portion <NUM>. The tether <NUM> comprises an unattached portion <NUM> between the first and second attachment regions. The configuration of the tether <NUM> with an unattached portion permits the detachable portion <NUM> to move away from the airbag device <NUM>. When the airbag device <NUM> is positioned underneath the panel <NUM> then the configuration of the tether <NUM> with an unattached portion permits the detachable portion <NUM> to move up and away from the airbag device <NUM>. In both cases, the tether then reaches full extension and thus causes the detachable portion <NUM> to rotate relative to the fixed portion <NUM>. The tether <NUM> defines a rotation axis that the detachable portion <NUM> rotates about. The rotation axis is controlled by the length of the unattached portion <NUM>. In this way, the distance of the rotation axis from the fixed portion <NUM> is defined by the length of the unattached portion <NUM>.

<FIG> shows a close-up view of a region of the panel. The vehicle may comprise a hinge <NUM> which is attached between the detachable portion <NUM> and the fixed portion <NUM>. The hinge <NUM> may run along one portion of the break line <NUM>. The hinge <NUM> defines a motion path of the detachable portion <NUM> as the panel <NUM> is forced by the airbag <NUM>. The rotation axis of the detachable portion <NUM> is defined by the rotation axis of the hinge. The rotation axis may be aligned with the portion of the break line <NUM> along which the hinge <NUM> runs. The hinge <NUM> may be combined with the tether <NUM> as shown in <FIG>. In this case, the tether <NUM> may provide an additional safety feature in the situation where the hinge <NUM> cannot take the load associated with the expansion of the airbag <NUM>. Alternatively, the hinge <NUM> may be configured to break after controlling the initial rotation of the detachable portion <NUM>. In this way, the hinge <NUM> may be frangible.

As discussed herein, the position of the airbag <NUM> relative to the break line <NUM> can be selected to cause the panel <NUM> to start tearing in a particular location. The position of the airbag <NUM> may be selected to mean that the expansion of the airbag <NUM> causes the panel to tear starting from a portion of the break line <NUM> that is remote from the tether <NUM>. The tether <NUM> may be attached to one side of the detachable portion <NUM> and the position of the airbag <NUM> is selected to cause the panel to tear initially on the opposite side of the detachable portion <NUM>. The tether <NUM> may be attached to the fixed portion <NUM> in a position remote from where an occupant of the vehicle <NUM> would sit. In this way, the detachable portion <NUM> is caused to rotate away from where an occupant of the vehicle <NUM> would sit.

The composite material panel <NUM> is likely to have sharp edges along the break line <NUM> once the panel <NUM> has torn. This may cause the airbag <NUM> to be punctured during inflation. To assist in avoiding puncturing the airbag <NUM> in this situation, the vehicle <NUM> may comprise a first protection flap <NUM>. The first protection flap <NUM> has an initial configuration as shown in <FIG>. The initial configuration may be a folded configuration. The first protection flap <NUM> has a deployed configuration as shown in <FIG>. In the initial configuration, the first protection flap <NUM> is attached to the vehicle <NUM> at one end of the first protection flap <NUM>. The opposite end of the first protection flap <NUM> is unattached to permit it to move during expansion of the airbag <NUM>. The first protection flap <NUM> may be folded up in the initial configuration. The first protection flap <NUM> may be folded up so that it sits on the surface of the airbag <NUM> that will be forced away from the rest of the airbag device <NUM> during expansion of the airbag. The first protection flap <NUM> may be folded up and attached to the surface of the panel <NUM> that faces the airbag device <NUM>. The first protection flap <NUM> is forced to move from the initial configuration to the deployed configuration during movement of the airbag <NUM> to the expanded configuration. The first protection flap <NUM> may be attached to the vehicle <NUM> so that when forced into the deployed configuration the first protection flap covers an edge <NUM> of the panel that runs along one side of the break line. The first protection flap <NUM> may be attached to the vehicle <NUM> so that when forced into the deployed configuration the first protection flap covers multiple sides of the break line. It may cover three sides of the break line <NUM>. It may cover all sides of the break line <NUM>. The first protection flap <NUM> may cover all but one portion of the break line. This portion being the part where the detachable portion <NUM> is closest to once detached from the rest of the panel <NUM>. The edge <NUM> being formed by the tearing of the panel due to the airbag moving to the expanded configuration.

The vehicle <NUM> comprises a second protection flap <NUM>. The second protection flap <NUM> has an initial configuration as shown in <FIG>. The second protection flap <NUM> has an extended configuration as shown in <FIG>. In the initial configuration, the second protection flap <NUM> is attached to the detachable portion <NUM> at one end of the second protection flap <NUM>. The opposite end of the second protection flap <NUM> is unattached to permit it to move during expansion of the airbag <NUM>. The second protection flap may be folded up in the initial configuration. The second protection flap <NUM> may lay underneath the panel <NUM> in the initial configuration. The second protection flap <NUM> moves with the detachable portion <NUM> as the detachable portion <NUM> moves due to being forced by the airbag <NUM> moving to its expanded configuration. The second protection flap <NUM> is forced to move to its extended configuration during the movement of the detachable portion <NUM>. The second protection flap <NUM> covers at least one edge of the detachable portion once the detachable portion <NUM> is at least partially detached. The second protection flap <NUM> may cover an edge of the detachable portion <NUM> which is remote from the tether <NUM>.

<FIG> shows a close-up cut-through view of part of the panel <NUM> and the airbag device <NUM>. The airbag device <NUM> is shown schematically in <FIG> without showing any of the components comprised as part of the airbag device <NUM>. <FIG> shows one configuration of the break line <NUM> where the break line <NUM> is formed as a channel in the panel <NUM>. <FIG> shows the break line <NUM> being offset from the aperture <NUM> of the airbag device <NUM>. The break line <NUM> is positioned outside of the aperture <NUM> in a direction perpendicular to the general movement direction of the airbag <NUM> as it moves to the expanded configuration.

<FIG> shows a first design of the break line <NUM>. <FIG> shows the surface of the panel <NUM> that faces the airbag device <NUM>. The break line <NUM> is a groove in the panel. The groove does not run through the whole thickness of the panel. In this way, the groove has a depth less than the panel thickness. The groove may be continuous as shown in <FIG>. <FIG> show the surface of the panel <NUM> that faces the airbag device <NUM>. As shown in <FIG>, the grove is broken by full thickness portions <NUM> of the panel. Not all of the full thickness portions <NUM> are labelled in <FIG> but it will be apparent that they are located between portions of the groove. In <FIG>, the groove is separated by full thickness portions <NUM> which have a length less than the length of each section of the groove <NUM>. In <FIG>, the groove <NUM> is separated by full thickness portions <NUM> which have a length which is comparable to the length of each section of the groove <NUM>.

The groove in the panel <NUM> may be formed by cutting the panel <NUM>. The cutting may use laser etching. The cutting may use a blade. The groove in the panel <NUM> may be formed during the lay-up process of the composite material panel <NUM>. <FIG> shows a cut-through view of the panel <NUM>. As shown in <FIG>, layers of reinforcement material may be laid-up with a gap to form the groove. A layer of reinforcement material may form a continuous layer <NUM> of the panel which forms the surface visible from within the vehicle. Other layers of reinforcement material form the gap in the side of the panel which forms the surface facing the airbag device. Whilst the thickness of the layers is shown as being approximately the same, it will be appreciated that different thicknesses may be used. The detachable portion <NUM> of the panel may be a different thickness than the fixed portion <NUM>. The detachable portion <NUM> may be thicker than the fixed portion <NUM>. The gap <NUM> may have angled sides rather than being perpendicular to the panel surface as shown in <FIG>. This may be achieved by the layers of reinforcement material having a staggered end at the gap so that the layers further from the continuous layer <NUM> form a larger gap <NUM> than those layers closer to the continuous layer <NUM>.

Once the reinforcement material has been laid-up it can be fixed in position using a forming technique such as RTM or by use of an autoclave if the reinforcement material already contains a matrix material.

<FIG> shows a second design of the break line <NUM>. <FIG> shows the surface of the panel <NUM> that faces the airbag device <NUM>. The break line <NUM> is formed of perforations in the panel along the break line. The perforations may be holes that run through part thickness or full thickness of the panel <NUM>. The perforations may be formed by micro-drilling the holes into the panel <NUM>. The micro-drilling may be performed by a physical micro-drill, by laser ablation and/or by chemical etching. The break line <NUM> may be formed by a series of micro-drilled holes. A surface layer may be present on the surface visible from within the vehicle. The surface layer may fill the perforations so that they do not run completely from one side of the panel <NUM> to the other. The surface layer may be a lacquer layer. The surface layer may be a paint layer. The surface layer may be a film applied to the panel <NUM>, such as a coverstock wrap layer. The coverstock wrap may be any suitable material such as leather, alcantara or vinyl.

It will be appreciated that any combination of the configurations shown in <FIG> could be combined together to form the break line <NUM>.

The panel forms a visible surface of the occupant cabin. One surface of the panel may face the occupant cabin whilst the opposite surface faces the airbag device <NUM>. The panel may form part of the facia of the occupant cabin. Thus, the airbag device covered by the panel may be a front airbag device in the occupant cabin. The airbag device may be a front passenger airbag device. The panel may form part of a pillar of the occupant cabin. The pillar may be located to one side of the occupant cabin. The pillar may be located beside a seat of the occupant cabin. Thus, the airbag deice covered by the panel may be a side airbag device in the occupant cabin. The panel may cover any suitable location of airbag device within the occupant cabin.

The use of a composite material panel to cover the airbag device can reduce the weight of the vehicle. Furthermore, by configuring the panel to have a break line rather than being formed of separate panels that are joined together a further weight saving can be gained as the join between the detachable portion and fixed portion is generated by the removal of material to form the break line. This compounds the benefit of using a composite material panel as a cover to an airbag. In addition, the break line has the function of weakening the material locally to ensure that the breakage of the panel happens along the break line. This avoids the panel shattering and causing sharp fragments of the panel to scatter around the occupant cabin. However, the weakening line is made in such a way that it is not visible from the occupant cabin so that it is imperceptible to an occupant in the cabin during normal use.

Claim 1:
A vehicle (<NUM>) comprising:
an airbag device (<NUM>) comprising a housing (<NUM>) and an airbag (<NUM>), the airbag having a packed configuration and an expanded configuration, the airbag expanding through an aperture (<NUM>) in the housing when moving from the packed configuration to the expanded configuration;
a composite material panel (<NUM>) positioned to cover the airbag device, the panel comprising a break line (<NUM>) running over the panel, a detachable portion (<NUM>) within the break line and a fixed portion (<NUM>) outside of the break line, the detachable portion becoming at least partially detached when the airbag forces the panel to tear along the break line, the break line being proximal to the aperture so that when the airbag moves to the expanded configuration the airbag forces the panel to tear along the break line;
a first protection flap (<NUM>), the first protection flap having an initial configuration where the first protection flap is located adjacent the airbag in the packed configuration and a deployed configuration where the first protection flap covers at least one edge of the panel that runs along one side of the break line when the panel has torn due to the airbag moving to the expanded configuration;
a tether (<NUM>) attached between the detachable portion and the fixed portion; and
a second protection flap (<NUM>), the second protection flap being attached to the detachable portion, the second protection flap being configured to cover at least one edge of the detachable portion once the detachable portion is at least partially detached.