TECHNICAL FIELD

This disclosure relates generally to vehicular airbag assemblies, and more particularly, to an airbag chute panel of a passenger airbag assembly and a method of manufacturing the same.

BACKGROUND

Passenger airbag assemblies are typically provided in the dashboard of a vehicle and are positioned in front of the passenger seat. Such an assembly generally includes a chute panel that forms part of an instrument panel of the vehicle, and a cannister that houses an airbag in a deflated or folded state. The chute panel may include a substrate, a chute, and a chute door, and when the airbag assembly is assembled, the airbag cannister is disposed within and secured to the chute. When the airbag is activated, the airbag inflates within the chute causing the chute door to rupture allowing the airbag to be blown out from the chute and the dashboard and into the cabin of the vehicle toward the passenger seat.

As described above, a chute panel of a passenger airbag assembly generally includes a substrate and a chute that is configured to house an airbag cannister. A conventional way of manufacturing such a chute panel includes forming the substrate and chute as two separate parts or components and then coupling them together using, for example, a welding process such as vibration welding, hot plate welding, or laser welding. This manufacturing process is not without its drawbacks, however.

For example, since the panel is constructed of two separate parts that have to be welded together, the panel is relatively heavy. Additionally, the required welding process results in a rather long manufacturing time, causes portions of the two components to melt, and requires the use of expensive equipment to perform the welding process.

Accordingly, there is a need for a passenger airbag chute panel and a method of manufacturing the same that minimizes and/or eliminates one or more of the above-identified deficiencies in conventional chute panels and chute panel manufacturing processes.

SUMMARY

In at least some implementations, a method of manufacturing a chute panel of an airbag assembly comprises forming a substrate from a first material wherein the substrate includes a body having a first end, a second end, and a longitudinal axis extending between the first and second ends, and a void residing in the body. The method further comprises forming a chute and a chute door from a second material, wherein a portion of the chute is molded onto the body of the substrate, and forming the chute door comprises filling in the void in the body of the substrate with the second material to form the chute door.

In at least some implementations, a chute panel for an airbag assembly comprises a substrate including a body having a first end, a second end opposite the first end, and a longitudinal axis extending therebetween, and a void residing in the body. The panel further includes a chute molded onto the substrate body and at least partially surrounding the void of the substrate, and a chute door formed in the void of the substrate.

In at least some implementations, a chute panel for an airbag assembly comprises a substrate including a body having a first end, a second end, and a longitudinal axis extending therebetween, a void residing in the body, and at least one chute door support structure connected to the body of the substrate and extending across at least a portion of the void of the substrate. The panel further includes a chute molded onto the substrate body and at least partially surrounding the void of the substrate, and a chute door formed in the void of the substrate. The chute door includes a first portion and second portion, wherein the first portion comprises the at least one chute door support structure and the second portion is molded onto the first portion.

Further aspects or areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings provided hereinafter. It should be understood that the summary and detailed description, including the disclosed embodiments and drawings, are merely illustrative in nature intended for purposes of illustration only and are not intended to limit the scope of the invention, its application or use. Thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the invention.

