Method and apparatus for forming an air bag deployment opening

Claim 1

An auto air bag installation of the type including inflatable air bag means, including a folded air bag and means for inflating said air bag, both stored behind an interior trip panel defined within the passenger compartment of an auto vehicle, said air bag inflated to be deployed into said passenger compartment during a collision through an opening formed in said trim panel, said trim panel comprised of an outer decorative skin layer, a foam core laying beneath said decorative skin layer, and a rigid backing layer underlying said foam core and decorative skin layer, said installation characterized by said backing layer being formed with a groove extending in a U shaped pattern to define an air bag deployment opening door shape in said trim panel, a bridging strip extending under said groove on either side thereof, said bridging strip fastened to said backing layer on one side of said groove lying outside said pattern and underlying but unattached to the backing layer within said groove pattern to provide support beneath said backing layer, means for applying concentrated energy to the inside of said trim panel in a delineated pattern int he shape of the required opening just prior to inflation of the air bag, said means including an elongated energy applying element extending in said U-shape pattern above said bridging strip and within said foam core whereby upon activation of said elongated element said foam core and decorative skin are degraded in said U-shaped pattern so that said door formed by said groove pattern and degraded foam core and skin layer may be pushed open by the inflating air bag thereby providing a deployment opening in said trim panel.