Apparatus for deploying an airbag through a hard panel

Claim 2

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door, the air bag dispenser configured to direct air bag deployment along a deployment path through the vehicle panel; the apparatus characterized by: a reaction plate disposed between the air bag and the air bag deployment door and configured to receive the force of air bag deployment from the dispenser and to direct and distribute that force against the door inner surface to separate the door from the vehicle panel along the frangible marginal edge of the door, the reaction plate being configured to bend under the force of air bag inflation causing a pivotable panel portion of the reaction plate to pivot into a position angularly spaced from the air bag deployment path to prevent the door from rebounding into the air bag, the pivotable panel portion of the reaction plate being separate from the door to allow the door and pivotable panel portion to move independently of each other following door separation.

Claim 3

A passive supplemental restraint apparatus as defined in claim 1 in which the door and vehicle panel comprise a single unitary piece.

Claim 4

A passive supplemental restraint apparatus as defined in claim 1 in which the reaction plate includes a marginal outer edge portion having a shape generally identical to and aligned with at least a portion of the frangible marginal edge of the air bag deployment door.

Claim 5

A passive supplemental restraint apparatus as defined in claim 1 in which the reaction plate is attached to the air bag dispenser along a reaction plate inner edge and in which an outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the attached reaction plate inner edge.

Claim 6

A passive supplemental restraint apparatus as defined in claim 4 further including a first flexible tether having an outer end portion fastened to the door and an inner end portion fastened to the air bag dispenser at a point adjacent the reaction plate inner edge.

Claim 7

A passive supplemental restraint apparatus as defined in claim 4 further including a stop member operatively connected between the reaction plate and the air bag dispenser.

Claim 8

A passive supplemental restraint apparatus as defined in claim 1 in which at least a portion of the reaction plate is disposed adjacent the door inner surface.

Claim 9

A passive supplemental restraint apparatus as defined in claim 1 in which the frangible marginal edge of the door comprises a region of reduced cross section.

Claim 10

A passive supplemental restraint apparatus as defined in claim 1 in which the air bag deployment door includes a rear marginal edge that forms a hinge between the vehicle panel and the door.

Claim 11

A passive supplemental restraint apparatus as defined in claim 1 in which a flexible skin covers at least a portion of the vehicle panel in a layered disposition.

Claim 12

A passive supplemental restraint apparatus as defined in claim 1 in which a foam layer covers at least a portion of the vehicle panel.

Claim 13

A passive supplemental restraint apparatus as defined in claim 1 in which the frangible marginal edge defines the entire air bag deployment door perimeter.

Claim 14

A passive supplemental restraint apparatus as defined in claim 12 in which a plurality of ribs extend integrally inward from an inner surface of the vehicle panel adjacent the frangible marginal edge of the door perimeter and are spaced apart around the door perimeter.

Claim 15

A passive supplemental restraint apparatus as defined in claim 12 in which the frangible marginal edge of the door comprises a region of reduced cross section.

Claim 16

A passive supplemental restraint apparatus as defined in claim 12 in which the reaction plate includes a marginal edge portion having a shape generally identical to and aligned with at least a portion of the frangible marginal edge of the air bag deployment door.

Claim 17

A passive supplemental restraint apparatus as defined in claim 12 in which the reaction plate is rigidly attached to the air bag dispenser along a reaction plate inner edge and in which an outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the rigidly attached reaction plate inner edge.

Claim 18

A passive supplemental restraint apparatus as defined in claim 1 further including a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the reaction plate being configured to bend and rotate the rotatable panel portion of the reaction plate more than 45 degrees into a position blocking the door from rebounding off the tether into the air bag.

Claim 19

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door to receive the force of air bag deployment from the dispenser and to direct and distribute that force against the door inner surface to separate the door from the vehicle panel along the frangible marginal edge of the door, at least a portion of the reaction plate disposed adjacent the door inner surface; at least one rib extending integrally inward from the door inner surface toward the reaction plate.

Claim 20

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door to receive the force of air bag deployment from the dispenser and to direct and distribute that force against the door inner surface to separate the door from the vehicle panel along the frangible marginal edge of the door, at least a portion of the reaction plate disposed adjacent the door inner surface; at least one rib extending integrally inward from the door inner surface toward the reaction plate.

Claim 21

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door to receive the force of air bag deployment from the dispenser and to direct and distribute that force against the door inner surface to separate the door from the vehicle panel along the frangible marginal edge of the door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the first flexible tether slidably engaging the door.

Claim 22

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door to receive the force of air bag deployment from the dispenser and to direct and distribute that force against the door inner surface to separate the door from the vehicle panel along the frangible marginal edge of the door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the first flexible tether slidably engaging the door.

Claim 23

A passive supplemental restraint apparatus as defined in claim 19 in which a strap is fastened to the door at first and second spaced attachment points, a portion of the first flexible tether slidably extending between the door and the strap and between the first and second attachment points.

Claim 24

A passive supplemental restraint apparatus as defined in claim 13 in which: first and second bosses extend inward from the door inner surface to the respective first and second attachment points; and first and second fasteners attach the strap to the respective first and second bosses.

Claim 25

A passive supplemental restraint apparatus as defined in claim 20 in which the first flexible tether engages the reaction plate.

Claim 26

A passive supplemental restraint apparatus as defined in claim 22 in which: the reaction plate is attached to the air bag dispenser along a reaction plate inner edge; an outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a hinge line extending parallel to the reaction plate inner edge; the first flexible tether includes a tether loop extending from at least one tether loop attachment portion, the tether loop attachment portion fastened to at least one of the air bag dispenser, the vehicle panel and the reaction plate adjacent the reaction plate hinge line; a middle tether portion of the first flexible tether is disposed between first and second tether loop ends and slidably engages the outer portion of the reaction plate; and an outer portion of the first flexible tether disposed between the middle tether portion and the first tether loop end slidably extends between the door and the strap.

Claim 27

A passive supplemental restraint apparatus as defined in claim 23 in which an upper edge portion of the frangible marginal edge of the door extends generally parallel to and is spaced from the reaction plate hinge line.

Claim 28

A passive supplemental restraint apparatus as defined in claim 23 in which the first flexible tether slidably extends through an opening in the outer portion of the reaction plate adjacent a reaction plate outer marginal edge.

Claim 29

A passive supplemental restraint apparatus as defined in claim 19 in which at least one additional flexible tether slidably engages the door.

Claim 30

A passive supplemental restraint apparatus as defined in claim 19 in which the reaction plate is attached to the air bag dispenser along a reaction plate inner edge and the first tether has an inner end portion fastened to the air bag dispenser at a point adjacent the reaction plate inner edge.

Claim 31

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the first tether having an outer end portion fastened to the door inner surface by at least one heat-staked pin, the pin extending integrally inward from the air bag deployment door.

Claim 32

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the first tether having an outer end portion fastened to the door inner surface by at least one heat-staked pin, the pin extending integrally inward from the air bag deployment door.

Claim 33

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the tether being fastened to the door inner surface by a screw threaded into a boss, the boss extending integrally inward from the air bag deployment door.

Claim 34

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the tether being fastened to the door inner surface by a screw threaded into a boss, the boss extending integrally inward from the air bag deployment door.

Claim 35

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the door including at least one fastener bracket extending integrally inward toward the air bag dispenser from the door inner surface, the fastener bracket including an attachment surface spaced inwardly from the door inner surface, the first tether attached to the attachment surface by a fastener.

Claim 36

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; and a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel, the door including at least one fastener bracket extending integrally inward toward the air bag dispenser from the door inner surface, the fastener bracket including an attachment surface spaced inwardly from the door inner surface, the first tether attached to the attachment surface by a fastener.

Claim 37

A passive supplemental restraint apparatus a defined in claim 30 in which the fastener bracket includes a fastener aperture disposed through the attachment surface of the bracket and in which the fastener comprises a rivet having a shaft portion extending through the aperture.

Claim 38

A passive supplemental restraint apparatus as defined in claim 30 in which at least one fastener bracket extends integrally inward from the door inner surface adjacent a lower marginal region of the door to a point adjacent the reaction plate.

Claim 39

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel; and a second flexible tether having an inner end portion fastened to at least one of the air bag dispenser and the vehicle panel, the first tether having an outer end portion fastened to a forward portion of the door adjacent a forward marginal edge of the door, the second flexible tether having an outer end portion fastened to an aft portion of the door.

Claim 40

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door; a first flexible tether connected to the door and fastened to at least one of the air bag dispenser and the vehicle panel; and a second flexible tether having an inner end portion fastened to at least one of the air bag dispenser and the vehicle panel, the first tether having an outer end portion fastened to a forward portion of the door adjacent a forward marginal edge of the door, the second flexible tether having an outer end portion fastened to an aft portion of the door.

Claim 41

A passive supplemental restraint apparatus as defined in claim 33 in which a single sheet of flexible material comprises both the first and second tethers.

Claim 42

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the air bag deployment door including a rear marginal edge that forms a hinge between the vehicle panel and the door, the air bag receptacle including a mouth disposed adjacent the air bag deployment door, the mouth having a width measured across the mouth in a direction perpendicular to the hinge, the hinge spaced from the mouth a distance equal to at least half of the mouth width.

Claim 43

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the air bag deployment door including a rear marginal edge that forms a hinge between the vehicle panel and the door, the air bag receptacle including a mouth disposed adjacent the air bag deployment door, the mouth having a width measured across the mouth in a direction perpendicular to the hinge, the hinge spaced from the mouth a distance equal to at least half of the mouth width.

Claim 44

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the reaction plate being attached to the air bag dispenser along a reaction plate inner edge and an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the attached reaction plate inner edge; a stop member operatively connected between the reaction plate and at least one of the air bag dispenser and the vehicle panel, the stop member being connected to the reaction plate at a stop point disposed between the first hinge line and a reaction plate outer marginal edge opposite the reaction plate inner edge; and the outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a second hinge line extending adjacent the stop point and generally parallel to the first hinge line, the second hinge line spaced between the first hinge line and the reaction plate outer marginal edge.

Claim 45

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the reaction plate being attached to the air bag dispenser along a reaction plate inner edge and an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the attached reaction plate inner edge; a stop member operatively connected between the reaction plate and at least one of the air bag dispenser and the vehicle panel, the stop member being connected to the reaction plate at a stop point disposed between the first hinge line and a reaction plate outer marginal edge opposite the reaction plate inner edge; and the outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a second hinge line extending adjacent the stop point and generally parallel to the first hinge line, the second hinge line spaced between the first hinge line and the reaction plate outer marginal edge.

Claim 46

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the reaction plate being attached to the air bag dispenser along a reaction plate inner edge and an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the attached reaction plate inner edge; a stop member operatively connected between the reaction plate and at least one of the air bag dispenser and the vehicle panel, the stop member including a pin having an elongated shaft portion and a stop flange disposed at an inner distal end of the shaft portion, the shaft portion having a central longitudinal axis and a width measured across the shaft portion in a direction perpendicular to the axis, the stop flange extending integrally and radially outward from the shaft portion, the air bag dispenser including an elongated slot having a slot width slightly greater than that of the stop member shaft portion, the stop member shaft portion slidably disposed within the slot, the stop member movable between a stowed position and a deployed position under the force of an inflating air bag, the stop flange being engaged with the slot in the deployed position.

Claim 47

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the reaction plate being attached to the air bag dispenser along a reaction plate inner edge and an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the attached reaction plate inner edge; a stop member operatively connected between the reaction plate and at least one of the air bag dispenser and the vehicle panel, the stop member including a pin having an elongated shaft portion and a stop flange disposed at an inner distal end of the shaft portion, the shaft portion having a central longitudinal axis and a width measured across the shaft portion in a direction perpendicular to the axis, the stop flange extending integrally and radially outward from the shaft portion, the air bag dispenser including an elongated slot having a slot width slightly greater than that of the stop member shaft portion, the stop member shaft portion slidably disposed within the slot, the stop member movable between a stowed position and a deployed position under the force of an inflating air bag, the stop flange being engaged with the slot in the deployed position.

Claim 48

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, at least one rib extending integrally inward from the door inner surface to a point adjacent the reaction plate.

Claim 49

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, at least one rib extending integrally inward from the door inner surface to a point adjacent the reaction plate.

Claim 50

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, and a flexible tether fastened between the door and the reaction plate.

Claim 51

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, and a flexible tether fastened between the door and the reaction plate.

Claim 52

A passive supplemental restraint apparatus as defined in claim 39 in which the tether includes an inner end portion fastened to the door, an outer end portion fastened to the door and a middle portion fastened to the reaction plate, the middle portion of the tether disposed between the inner and outer end portions of the tether.

Claim 53

A passive supplemental restraint apparatus as defined in claim 39 in which the door includes a fastener bracket extending integrally inward toward the air bag dispenser from the door inner surface, the fastener bracket including an attachment surface spaced inwardly from the door inner surface, the tether attached to the attachment surface by a fastener.

Claim 54

A passive supplemental restraint apparatus as defined in claim 41 in which the fastener bracket includes a fastener aperture disposed through the attachment surface of the bracket and in which the fastener comprises a rivet having a shaft portion extending through the aperture.

Claim 55

A passive supplemental restraint apparatus as defined in claim 39 in which the tether is fastened to the door inner surface by at least one heat-staked pin, the pin extending integrally inward from the air bag deployment door.

Claim 56

A passive supplemental restraint apparatus as defined in claim 39 in which the tether is fastened to the door inner surface by a screw threaded into a boss, the boss extending integrally inward from the air bag deployment door.

Claim 57

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, the reaction plate being rigidly attached to the air bag dispenser and the vehicle panel along a reaction plate inner edge, an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the rigidly attached reaction plate inner edge; a flexible tether fastened between the door and the reaction plate; and a stop member operatively connected between the reaction plate and the air bag dispenser.

Claim 58

A passive supplemental restraint apparatus for an automotive vehicle, the apparatus comprising: an interior vehicle panel; an air bag deployment door integrally formed in the vehicle panel, the air bag deployment door having a perimeter, at least a portion of the perimeter defined by a frangible marginal edge; an air bag dispenser supported adjacent a door inner surface opposite a door outer surface; an air bag supported in an air bag receptacle of the air bag dispenser, the air bag having an inner end operatively connected to the air bag dispenser and an outer end disposed adjacent the air bag deployment door; a reaction plate disposed between the air bag and the air bag deployment door, the frangible marginal edge defining the entire air bag deployment door perimeter, the reaction plate being rigidly attached to the air bag dispenser and the vehicle panel along a reaction plate inner edge, an outer portion of the reaction plate being outwardly pivotable away from the air bag dispenser by bending the reaction plate along a first hinge line extending parallel to the rigidly attached reaction plate inner edge; a flexible tether fastened between the door and the reaction plate; and a stop member operatively connected between the reaction plate and the air bag dispenser.

Claim 59

A passive supplemental restraint apparatus as defined in claim 45 in which: the stop member is connected to the reaction plate at a stop point disposed between the first hinge line and a reaction plate outer marginal edge opposite the reaction plate inner edge; the outer portion of the reaction plate is outwardly pivotable away from the air bag dispenser by bending the reaction plate along a second hinge line extending adjacent the stop point and generally parallel to the first hinge line, the second hinge line spaced between the first hinge line and the reaction plate outer marginal edge; and the tether is attached to the reaction plate between the second hinge line and the reaction plate outer marginal edge.

Claim 60

A passive supplemental restraint apparatus as defined in claim 46 in which: the stop member includes a pin having an elongated shaft portion and a stop flange disposed at an inner distal end of the shaft portion, the shaft portion having a central longitudinal axis and a width measured across the shaft portion in a direction perpendicular to the axis, the stop flange extending integrally and radially outward from the shaft portion; and in which the air bag dispenser includes an elongated slot having a slot width slightly greater than that of the stop member shaft portion, the stop member shaft portion slidably disposed within the slot, the stop member movable between a stowed position and a deployed position under the force of an inflating air bag, the stop flange being engaged with the slot in the deployed position.