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. 2Page: Previous 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Next
Last modified: September 9, 2013