Appeal No. 2006-2962
Application No. 10/252,177
THE INVENTION
The invention relates to a method of making a unitary composite cover for a
motor vehicle inflatable air bag system. Representative claim 25 reads as follows:
25. A method of making a unitary composite air
bag cover for an inflatable air bag system, the method
comprising the steps of:
injecting a molten first plastic into a mold cavity of
a first mold having a shape defining a body of the air bag
cover, wherein the shape defining a body includes a
shape defining a front panel;
permitting the first plastic to cool to a temperature
beneath the softening point of the first plastic such that a
body having a front panel is formed;
removing the body from the first mold;
inserting the body into a mold cavity of a second
mold having a shape defining the entire air bag cover
including an outer layer having a contact surface;
injecting a molten second plastic into the mold
cavity of the second mold at a temperature and pressure
sufficient to melt the front panel of the body and to form
the outer layer;
permitting the second plastic to cool to a
temperature beneath the softening point of the first and
second plastics such that the unitary composite air bag
cover is formed, wherein a molecular concentration
gradient is formed at an interface between the first and
second plastics to bond the first and second plastics by
diffusion at the entire contact surface of the outer layer to
prevent separation of the outer layer from the front panel
during use of the air bag cover; and
removing the completed air bag cover from the
second mold.
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