Invisible airbag door having reinforced PVC shell

Claim 2

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a rupturable thermoplastic shell covering the substrate and the door, the plastic shell being reinforced with an adhesive coating that is flexible and remains pliable throughout the operational temperature range of the invisible airbag door, and that is equal to at least about 40% the thickness of the shell.

Claim 3

The invisible airbag door arrangement as defined in claim 1 wherein the shell is reinforced with a urethane coating.

Claim 4

The invisible airbag door arrangement as defined in claim 2 wherein the urethane adhesive coating has a thickness that is sufficient to dominate the physical characteristics of the shell.

Claim 5

The invisible airbag door arrangement as defined in claim 2 wherein the adhesive coating is a thermosetting urethane adhesive that cures to form a flexible non-porous laminate or layer on the back side of the shell.

Claim 6

The invisible airbag door arrangement as defined in claim 4 wherein the adhesive coating is cut through and the back side of the shell is scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the shell.

Claim 7

The invisible airbag door arrangement as defined in claim 4 wherein the airbag adhesive coating is applied to the entire back side of the PVC-shell.

Claim 8

The invisible airbag door arrangement as defined in claim 4 wherein the adhesive coating is applied at least to the area for creating an airbag opening in the PVC shell and a significant marginal portion surrounding the area for creating the airbag opening.

Claim 9

The invisible airbag door arrangement as defined in claim 1 further comprising an elastomeric foam layer that is bonded to the thermoplastic shell by the adhesive coating.

Claim 10

The invisible airbag door arrangement as defined in claim 4 wherein the coated PVC shell is spaced from the substrate and the attached door by an elastomeric urethane foam layer that is bonded to the PVC shell by the adhesive reinforcement coating.

Claim 11

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with an adhesive coating that is flexible and remains pliable throughout an operational temperature range from about -20 degrees fahrenheit to about 170 degrees fahrenheit to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures.

Claim 12

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with an adhesive coating that is flexible and remains pliable throughout an operational temperature range from about -20 degrees fahrenheit to about 170 degrees fahrenheit to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures.

Claim 13

The invisible airbag door arrangement as defined in claim 10 wherein the adhesive coating is a urethane adhesive coating that has a thickness sufficient to dominate the physical characteristics of the PVC shell throughout the operational temperature range.

Claim 14

The invisible airbag door arrangement as defined in claim 10 wherein the adhesive coating is a thermosetting urethane adhesive that cures to form a flexible non-porous layer on the back side of the PVC shell.

Claim 15

The invisible airbag door arrangement as defined in claim 10 wherein the adhesive coating is cut through and the back side of the PVC shell is scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the PVC shell.

Claim 16

The invisible airbag door arrangement as defined in claim 10 wherein the adhesive coating is applied to the entire back side of the PVC shell.

Claim 17

The invisible airbag door arrangement as defined in claim 13 wherein the adhesive coating is applied at least to the area for creating an airbag opening in the PVC shell and a significant marginal portion surrounding the area.

Claim 18

The invisible airbag door arrangement as defined in claim 10 further comprising an elastomeric urethane foam layer that is covered by the coated polyvinyl chloride (PVC) shell.

Claim 19

The invisible door arrangement as defined in claim 11 wherein the coated PVC shell is spaced from the substrate and the attached door by an elastomeric urethane foam layer that is bonded to the PVC shell.

Claim 20

The invisible door arrangement as defined in claim 12 further comprising an elastomeric urethane foam layer that is covered by the coated polyvinyl chloride (PVC) shell, the adhesion of the PVC shell to the elastomeric urethane foam layer being enhanced by the urethane adhesive reinforcement layer.

Claim 21

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with a thermosetting urethane adhesive that cures to form a non-porous coating on the back side of the PVC shell that is flexible and remains pliable throughout an operational temperature range from about -20° F. to about 170° F. to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, the coating being cut through and the back side of the PVC shell being scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the PVC shell, and an elastomeric urethane foam layer that is bonded to the polyvinyl chloride (PVC) shell by the urethane adhesive coating.

Claim 22

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with a thermosetting urethane adhesive that cures to form a non-porous coating on the back side of the PVC shell that is flexible and remains pliable throughout an operational temperature range from about -20° F. to about 170° F. to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, the coating being cut through and the back side of the PVC shell being scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the PVC shell, and an elastomeric urethane foam layer that is bonded to the polyvinyl chloride (PVC) shell by the urethane adhesive coating.

Claim 23

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with a thermosetting urethane adhesive that cures to form a non-porous coating on the back side of the PVC shell that is flexible and remains pliable throughout an operational temperature range from about -20° F. to about 170° F. to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, the coating being cut through and the back side of the PVC shell being scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the PVC shell, an elastomeric urethane foam layer that is bonded to the polyvinyl chloride (PVC) shell by the urethane adhesive coating, and the PVC shell having a thickness in a range from about 0.030 inches to about 0.050 inches and the urethane adhesive coating having a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 24

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and the decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with a thermosetting urethane adhesive that cures to form a non-porous coating on the back side of the PVC shell that is flexible and remains pliable throughout an operational temperature range from about -20° F. to about 170° F. to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, the coating being cut through and the back side of the PVC shell being scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the PVC shell, an elastomeric urethane foam layer that is bonded to the polyvinyl chloride (PVC) shell by the urethane adhesive coating, and the PVC shell having a thickness in a range from about 0.030 inches to about 0.050 inches and the urethane adhesive coating having a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 25

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and a decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag; at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with an adhesive coating that is flexible and remains pliable throughout an operational temperature range from about -20 degrees fahrenheit to about 170 degrees fahrenheit to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, and the PVC shell having a thickness in a range from about 0.030 inches to about 0.050 inches and the urethane adhesive coating having a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 26

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and a decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag; at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride (PVC) shell covering the substrate and the door, the PVC shell being reinforced with an adhesive coating that is flexible and remains pliable throughout an operational temperature range from about -20 degrees fahrenheit to about 170 degrees fahrenheit to reduce fragmentation of the PVC shell when the airbag is deployed at low temperatures and to reduce stretching of the PVC shell and the time required to rupture the PVC shell when the airbag is deployed at high temperatures, and the PVC shell having a thickness in a range from about 0.030 inches to about 0.050 inches and the urethane adhesive coating having a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 27

The invisible airbag door arrangement as defined in claim 1 wherein the adhesive coating has a thickness that ranges from about 40% to about 80% of the thickness of the shell.

Claim 28

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and a decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride shell covering the substrate and the door that has a thickness in a range from about 0.030 inches to about 0.050 inches, and the shell being reinforced with an adhesive coating that has a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 29

An invisible airbag door arrangement for providing an opening in a decorative panel for the deployment of an airbag that is covered by the decorative panel comprising; a substrate that is adapted for securement between a deflated airbag and a decorative panel covering the deflated airbag and that defines an opening for deployment of the airbag, at least one door that is connected to the substrate for swinging from a closed position behind the decorative panel to an open position extending through the decorative panel, and a polyvinyl chloride shell covering the substrate and the door that has a thickness in a range from about 0.030 inches to about 0.050 inches, and the shell being reinforced with an adhesive coating that has a thickness in a range from about 0.020 inches to about 0.040 inches.

Claim 30

The invisible airbag door arrangement as defined in claim 23 wherein the shell is reinforced with a thermosetting urethane adhesive coating, wherein the coating is cut through and the back side of the shell is scored or notched to provide weakened areas or tear lines that define an area for creating an airbag opening in the shell, and wherein an elastomeric foam layer is bonded to the shell by the urethane adhesive coating.