An automobile airbag device having a lid in an instrument panel body, where the instrument panel body faces an airbag pop-out area, the lid for airbag expansion is formed into the instrument panel body by a hinge section and a splitting section of thinned thicknesses. There is an opening formed by breaking of the splitting section and swinging of the lid about the hinge section where an airbag which expands from airbag device body can push through around the opening. There is a reinforcement bracket which is proximate to the inner side of the lid.

An instrument panel has an air bag door to be bent and opened toward a windshield. The air bag door has a door core. An edge of the door core on the windshield side and an edge of a frame arranged on the edge of the door core on the windshield side are fixed to the windshield-side peripheral edge of an air bag opening of an instrument panel core. The door core and frame are provided with extensions on the windshield side. Each of the extensions has a rigidity-lowering opening, and an end of each extension on the windshield side has a fixing part to be fixed to the instrument panel core.

A vehicle occupant safety apparatus (10) for inserting into and covering an opening (22) of an instrument panel (12) comprises an air bag module (14). The air bag module (14) has an air bag (50), which is inflatable through the opening (22) in the instrument panel (12) for protecting a vehicle occupant during a crash condition. The apparatus (10) further comprises a door (16) for covering the opening (22) in the instrument panel (12). The door (16) is attached to the air bag module (14) and is movable relative to the air bag module (14) to locate the door (16) relative to the instrument panel (12). The door (16) and the instrument panel (12) have respective interlocking portions (34 and 90), which snap together to attach the door (16) to the instrument panel (12). The interlocking portions (34 and 90) snap together when the air bag module (14) is inserted into the opening (22) in the instrument panel (22) and the door (16) is moved relative to the air bag module (14) into a position to cover the opening (22). The interlocking portions (34) of the instrument panel (12) are deflected when the respective interlocking portions (34 and 90) of the door (16) and the instrument panel (12) snap together.

A molded instrument panel having a plastic front panel and incorporating an integral air bag door is disclosed wherein the air bag door is hinged to the front panel by overlapping integral plastic members to ensure that the door does not separate from the instrument panel during air bag deployment. The instrument panel also includes a plastic frame integrally formed on an inner surface of the front panel which together with the door, encloses an uninflated air bag. Preferably, the hinge and portions of the frame are formed by a pressurized fluid so as to be hollow, thereby facilitating swinging movement of the door while preventing sink marks on an outer surface of the front panel.

A method for forming an automotive instrument panel having a concealed door comprising a series of steps. A plastic parison is extruded to form the substrate layer of the instrument panel. The parison has first and second walls. The parison is placed within a mold and the first wall is contacted with the second wall to form a hinge. The area of contact forms a bond between the first and second walls. A different portion of the first and second walls are contacted to form an opening path. The opening path intersects the hinge. The opening path usually has a thickness much less than the thickness of the first and second walls to form an easily fracturable area. The door swings on the hinge to open. A elongated section of material on the second wall, enables the second wall to wrap along the hinge when the door is opened.