Most modern vehicles include inflatable restraint apparatus having deployable airbags positioned in many locations throughout an automotive vehicle. Generally, an interior panel includes a deployment door formed into the panel which is designed to break free upon deployment of the airbag.
A primary aim of the airbag assembly is to control the opening of the deployment door to avoid break explosion and the possibility of flying parts. Clean deployment is achieved in some airbag assemblies by providing a deployment door with a seam, meaning the door is not physically interconnected with the surrounding interior panel. Unfortunately, the seam in the interior panel around the deployment door may not be visually appealing. Thus, in other airbag assemblies clean deployment is provided, in part, by a “seamless” deployment door having aggressive pre-weakening of the outline of the door (typically by laser scoring, mechanical scoring, etc.) by cutting the material or creating perforations.
While this weakening of seamless deployment doors is typically done on the underside of the panel, there still exists a potential for creating blemishes or other disturbances on the exposed class “A” surface. Furthermore, there is a potential to have an uneven break or tear in the deployment door since the plastic is not completely cut through. Accordingly, there exists a need to provide a seamless deployment door which quickly and reliably breaks free from the surrounding panel while eliminating the potential for surface blemishes due to pre-weakening of the door outline.