Patent ID: 7631890

Claim:
An instrument panel for an automotive vehicle that contains a defined air bag deployment door, comprising: a relatively rigid base substrate structure having an outer surface and an inner surface, wherein said substrate is formed to have a generally constant thickness between said inner and outer surfaces in the area surrounding the defined deployment door; an outer finish skin material being attached to and overlying said outer surface; said base structure being molded to define said inner and outer surfaces and a deployment door section; and said deployment door section being defined in said molded structure by reduced thicknesses in tear seams and hinge portions formed into said inner surface and maintaining said defined deployment door invisible from the outer surface, wherein said hinge portion of said deployment door is defined by a first predetermined apex thickness that is less than said general substrate thickness in the area surrounding the defined deployment door and said hinge will bend at the apex area and will not fracture and separate during deployment of the air bag, wherein said tear seams are defined by predetermined thicknesses that are less than said first apex thickness of said hinge portion, and wherein said tear seams include a first rupturable tear seam located opposite said hinge portion and having a lesser thickness as compared to the thicknesses of said hinge and other tear seams to cause said first tear seam to fracture and rupture prior to said other tear seams during deployment of said air bag.