Method for making an insert for air bag cover assembly

Claim 1

A method of molding a door as an integral part of an insert for an air bag cover in which the door conceals an air bag assembly and is adapted to provide an air bag deployment opening within the insert when the air bag impacts the door during air bag inflation, said method comprising the steps of: providing a mold having an insert cavity defined by an upper mold half and lower mold half, providing a plurality of blades for selective movement into said insert cavity so as to form a door cavity therein which is separated by the blades from a surrounding body portion of the insert cavity, and where at least one of the blades is formed with projections which extend into said body portion of the insert cavity, moving said plurality of blades into said insert cavity to form said door cavity with said one of said blades having the projections thereof extending into the adjacent body portion of said insert cavity, injecting into said body portion of the insert cavity a first compound of relatively rigid plastic material so that the first plastic material surrounds said blades and said door projections and fills said insert cavity in all areas except for the isolated door cavity portion to form a rigid body of the insert, removing said plurality of blades from said insert cavity so as to form a plurality of interlock openings in said first plastic material in the areas previously occupied by said blades, and injecting into said door portion of the cavity a second compound of plastic material which is compatible with but relatively more flexible than said first plastic material so as to bond said second plastic material to said first plastic material at an interface thereof and simultaneously filling said interlock openings with interlocking projections of the second material to form the door and provide a permanent interlocking connection between said door and the body of said insert in regions of the interlocking openings and projections.

Claim 2

A method of molding a door as an integral part of an insert for an air bag cover in which the door conceals an air bag assembly and is adapted to provide an air bag deployment opening within the insert when the air bag impacts the door during air bag inflation, said method comprising the steps of: providing a mold having an insert cavity defined by an upper mold half and lower mold half, providing a plurality of blades for selective movement into said insert cavity so as to form a door cavity therein which is separated by the blades from a surrounding body portion of the insert cavity, and where at least one of the blades is formed with projections which extend into said body portion of the insert cavity, moving said plurality of blades into said insert cavity to form said door cavity with said one of said blades having the projections thereof extending into the adjacent body portion of said insert cavity, injecting into said body portion of the insert cavity a first compound of relatively rigid plastic material so that the first plastic material surrounds said blades and said door projections and fills said insert cavity in all areas except for the isolated door cavity portion to form a rigid body of the insert, removing said plurality of blades from said insert cavity so as to form a plurality of interlock openings in said first plastic material in the areas previously occupied by said blades, and injecting into said door portion of the cavity a second compound of plastic material which is compatible with but relatively more flexible than said first plastic material so as to bond said second plastic material to said first plastic material at an interface thereof and simultaneously filling said interlock openings with interlocking projections of the second material to form the door and provide a permanent interlocking connection between said door and the body of said insert in regions of the interlocking openings and projections.

Claim 3

A method of molding a door as an integral part of an insert for an air bag cover in which the door conceals an air bag assembly and is adapted to provide an air bag deployment opening within the insert when the air bag impacts the door during air bag inflation, said method comprising the steps of: providing a mold having an insert cavity defined by an upper mold half and a lower mold half, forming a rectangular partition within the insert cavity isolating within its walls a door portion of the cavity from a surrounding body portion of the cavity and providing the partition with a plurality of projections extending into said body portion of the insert cavity along at least one of the four sides of the partition, injecting a first rigid thermoplastic material into the body portion of said insert cavity so that the first thermoplastic material surrounds said partition and its projections and fills said body portion of the insert cavity in all areas except for the door portion of the cavity to form a body of the insert, removing said partitions from said insert cavity so as to form a plurality of interlock openings in said first thermoplastic material and expose surfaces of the first thermoplastic material to said door portion of the cavity, and injecting into said door portion of the cavity a second flexible thermoplastic material which is compatible with said first thermoplastic material so as to bond said second thermoplastic material to said first thermoplastic material at said surfaces and simultaneously filling said interlock openings in said first thermoplastic material to form the door and provide an interlocking connection between said door and the body of said insert.

Claim 4

A method of molding a door as an integral part of an insert for an air bag cover in which the door conceals an air bag assembly and is adapted to provide an air bag deployment opening within the insert when the air bag impacts the door during air bag inflation, said method comprising the steps of: providing a mold having an insert cavity defined by an upper mold half and a lower mold half, forming a rectangular partition within the insert cavity isolating within its walls a door portion of the cavity from a surrounding body portion of the cavity and providing the partition with a plurality of projections extending into said body portion of the insert cavity along at least one of the four sides of the partition, injecting a first rigid thermoplastic material into the body portion of said insert cavity so that the first thermoplastic material surrounds said partition and its projections and fills said body portion of the insert cavity in all areas except for the door portion of the cavity to form a body of the insert, removing said partitions from said insert cavity so as to form a plurality of interlock openings in said first thermoplastic material and expose surfaces of the first thermoplastic material to said door portion of the cavity, and injecting into said door portion of the cavity a second flexible thermoplastic material which is compatible with said first thermoplastic material so as to bond said second thermoplastic material to said first thermoplastic material at said surfaces and simultaneously filling said interlock openings in said first thermoplastic material to form the door and provide an interlocking connection between said door and the body of said insert.