Patent ID: 8336908

Claim:
An automotive air bag system for a vehicle, comprising: an instrument panel substrate comprising a first moldable thermoplastic characterized by a first melting temperature, wherein the instrument panel substrate has a substantially smooth outer surface concealing an air bag deployment door and facing a passenger compartment of the vehicle; and a chute comprising a second moldable thermoplastic characterized by a second melting temperature lower than the first melting temperature, wherein the chute includes an in-mold tear seam and a hinge for the air bag deployment door, wherein the in-mold tear seam has a tip extending toward the instrument panel substrate, wherein the chute includes a passageway for guiding an inflating air bag to the deployment door, wherein the chute is attached to an inner surface of the instrument panel substrate by insert molding in which injection of the first moldable thermoplastic caused a partial melting of the second moldable thermoplastic, and wherein extension of the tip results in molding the instrument panel substrate with a narrowed thickness without a read-through defect on the smooth outer surface.