CA2006284C

CA2006284C - Cover for a vehicle air bag

Info

Publication number: CA2006284C
Application number: CA002006284A
Authority: CA
Inventors: Masami Sawada; Yuichi Nanbu; Mitsuo Yoshiyasu
Original assignee: Takata Corp
Current assignee: Takata Corp
Priority date: 1988-12-26
Filing date: 1989-12-21
Publication date: 1995-05-09
Anticipated expiration: 2009-12-21
Also published as: FR2640922A1; USRE36898E; US5110647A; CA2006284A1; GB2228235A; GB2228235B; FR2640922B1; GB8929115D0; DE8915085U1

Abstract

A cover for a vehicle air bag comprises an external surface layer injection-molded from a thermoplastic material having a JIS-A hardness of 20 to 90 and a core layer injection-molded from a thermoplastic material having a bending elastic modulus (JIS K 7203) of not less than about 1000 kg/cm2 and a hardness greater than that of the surface layer. The core has weakened zones along which the cover breaks when the air bag is inflated.

Description

~2~)06284 Description Cover for a Vehicle Air Bag Field of the Invention The present invention relates to a cover for housing a folded vehicle safety air bag of the type that inflates virtually instantaneously upon the sensing of a rapid acceleration of the vehicle or some other event indicative of a collision of the vehicle and prevents the occupant from experiencing a secondary collision with parts of the vehicle, such as the steering wheel, dashboard or windshield, generally in front of him.

Background of the Invention Vehicle safety air bags are folded into a housing formed in part by a support that is attached to the vehicle, for example, the hub of the steering wheel, and to which the air bag is secured, and in part by a cover that is positioned generally between the folded air bag and the vehicle occupant. In a widely used type of air bag housing, the cover is made of a polymeric material and has weakened zones that enable it to break easily in a controlled manner when the air bag inflates, thereby enabling the air bag to emerge from the housing and fully inflate. With such a type of cover it is, of course, very important that pieces of the cover are not broken free and propelled toward the vehicle occupants, lest the occupants be injured by the flying pieces. A common way of ensuring that the cover is not broken into loose pieces is to provide reinforcing, commonly a net, to keep broken pieces of the cover from scattering. Examples of covers having reinforcing are disclosed in Japanese published patent ~' Z(106Z~3~

applications Nos. 234764/1987 and 127336/1975 and Japanese published utility model applications Nos.
80928/1977, 43454/1975 and 25342/1976.
Covers with reinforcing nets are commonly made from a polymeric material with a relatively low strength, such as polyurethane foam. The net reinforcement is molded into the cover material and is interrupted to form zones of weakness so that the cover can be broken easily along those zones when the air bag inflates.
Japanese published utility model application No.
76042/1977 describes and shows an air bag cover having an external surface layer or skin of a hard polyurethane foam that provides a smooth external surface finish and a core of a low-density polyurethane foam that imparts softness (yieldability) to the cover as a whole. Zones of weakness in the form of slits or grooves are formed in the core to facilitate breaking of the cover.
The manufacture of air bags with reinforcing nets involves many steps, and it is difficult to make them with high accuracy, even when Reaction Injection Molding (RIM) is used, thus leading to a low yield rate and a high production cost.
The cover of Japanese Published Appln. No.
76042/1977 has a hard surface (Shore Hardness, 30 to 40, ASTM-2240) which is uncomfortable to the occupant if he contacts it. Also, the cover materials are of low strength, and because there is no reinforcing net, the cover is prone to being fragmented into pieces that are scattered when the air bag inflates.

Summary of the Invention An object of the present invention is to provide an air bag cover that has a surface that is soft and comfortable to the touch and in which a core under the surface layer holds its shape well under external loads for protection of the air bag. Another object is to provide a cover that is easily broken in a controlled manner when the bag inflates over a temperature range of from -400C to 800C. When the cover breaks, no pieces are to be separated and scattered. Its appearance and performance are not to be significantly changed within the foregoing temperature range after exposing it to a temperature of 110oC for 500 hours. Still another object is to provide an air bag cover that can be produced easily and economically with accuracy and with a minimum of rejects.
In accordance with the invention an air bag cover is characterized in that it has an external surface layer formed of a thermoplastic polymeric material having a Type A hardness of from about 20 to about 90 as determined by Japanese Industrial Standard K6301-1975 and a core layer formed of thermoplastic polymeric material and having a modulus of elasticity in flexure of not less than about 1000 kg/cm2 as determined in accordance with Japanese Industrial Standard K7203-1982 and a hardness greater than that of the surface layer and in that the weakened zones are formed in the core layer.
For a better understanding of the invention reference may be made to the following description of the preferred embodiments and examles.
Description of the Drawin~s Fig. 1 is a side elevational view of an air bag assembly having a cover embodying the present invention, part of the cover being shown in cross-section; and Fig. 2 is a bottom plan view of the cover of Fig. 1.

Z~ 8~

Description of Embodiments The air bag assembly shown in the drawing comprises a cover 1, an air bag 2 folded into the housing or compartment formed by the cover 1, an inflator 3, and a retainer ring 4 that clamps an annular band of the air bag material adjacent the bag opening to a retainer base 5. The cover 1 is joined to the base 5 by rivets 6 and a ring or bands 7. An example of an air bag assembly similar to the one shown in the drawings and for which the cover of the present invention is well-suited is described and shown in British Patent Application No. 89 08643 filed April 17, 1989, which is incorporated by reference into the present specification. The present invention is, however, useful in a wide range of designs of air bag assemblies, including those that have covers of various shapes and configurations.
The cover 1 comprises an external surface layer lA
of a thermoplastic material having a Type A hardness of from about 20 to about 90 as determined by Japanese Industrial Standard K6301-1975 and a core lB of a thermoplastic material having a modulus of elasticity in flexure of not less than about 1000 kg/cm as determined by Japanese Industrial Standard K7203-1982 and a hardness greater than that of the material of the surface layer. The cover 1 has predetermined zones of weakness lC, such as grooves, slits or both grooves and slits, along which the core easily fractures when the air bag inflates. In the embodiment, the zones of weakness lC consist of bands of reduced thickness (grooves) and spaced-apart perforations extending lengthwise along the center and widthwise along each side of the main wall and grooves along each corner of the core lB. The perforations do not extend entirely through the surface layer but may extend partway into the inner face. Various configurations of weakened 2~ 28~

zones can be used in covers embodying the present invention, and the one shown in Fig. 2 is merely exemplary.
Thermoplastic materials suitable for the external surface layer lA include thermoplastic elastomers based on olefin, styrene, polyester, polyurethane, vinyl chloride or polyamid; polyolefin-based soft materials, such as ethylene-vinyl ester copolymers ( EVA), ethylene-~-olefin copolymers (especially those having ~-olefins with from 3 to 12 carbon atoms); ethylene-unsaturated carbonic acid and its derivatives and copolymers; and soft polyvinyl chloride. These materials may be used alone or may be blended. Among them olefin-, styrene- and vinyl chloride-based elastomers are desirable from the point of view of imparting a sense of softness to the cover.
The olefin- and styrene-based thermoplastic elastomers are especially preferred because of their ability to retain their softness over a broad range of temperatures. Suitable olefin-based thermoplastic elastomers include olefin-based rubbers, such as EPM, EPDM and ethylene-butene-l copolymer rubber, polypropylene, polyethylene, polyisobutylene and copolymers of propylene and ethylene. To obtain the desired softness in surface layers that incorporate olefin-based elastomers, it may be necessary to add a hydrocarbon-based rubber softener, such as paraffin-based oil or naphthene-based oil.
The styrene-based elastomers that can be used as the base polymer for the surface layer lA include block copolymers consisting of monovinyl aromatic hydrocarbon polymer blocks and conjugate diene elastomeric polymer blocks and the thermoplastic elastomers based on the hydrogenated derivatives of such block copolymers.
These base polymers can be obtained by the conventional method of living polymerization using lithium-based initiators. The styrene-based elastomer may also be the ZQ~284 hydrogenated derivatives of a block copolymers consisting of a styrene polymer blocks and butadiene or isoprene polymer blocks - these polymers are excellent in weatherability, thermal aging and softness adjustability.
The above olefin- and styrene-based thermoplastic elastomers may not only be used independently but also be blended at an appropriate ratio to make the surface layer lA. More specifically, the material of the surface layer lA may be a blend of the styrene-based thermoplastic elastomers mentioned above, an olefin- or styrene-based polymer, such as polyisobutylene, and a hydrocarbon-based rubber softener, as in the case of the above olefin-based elastomers to control the hardness and other qualities of the material.
The content of hydrocarbon-based rubber softener in the surface layer lA should not exceed 30% by weight. If it exceeds this level, the air bag cover may deteriorate in external appearance (deformation, etc.) after it is left at 110C for 500 hours, or it may break in places other than the weakened zones or allow broken pieces to scatter when the air bag inflates. Determining the content of the hydrocarbon-based rubber softener also requires taking into account 2S the hardness (the sense of softness) and the molding/processing properties. When all of these factors are considered, the amount should usually be less than 20% and, preferably, less than 10% by weight.
When a rubber softener is included, at least 1% and, preferably, more than 3% should be used.
The surface layer lA may incorporate inorganic fillers (e.g., calcium carbonate, silica, talc and the like), pigments and stabilizers. Materials with partial bridge structures made by the processes of 2Q~284 Japanese published patent application Nos. 26838/1971, 13541/1977, 37953/1977 and 98248/1981 may also be used in the surface layer lA.
Materials for the surface layer lA with hardnesses below JIS-A 20 are desirably soft to the touch but are poor in terms of processing, moldability and mechanical strength and, therefore, are unsatisfactory. Materials with JIS-A hardnesses greater than 90 present no problems of processing/molding but are undesirably hard. The particular hardness chosen for the surface layer lA depends to some extent on the thickness of the layer. Generally, it will be preferable to use a material with a hardness in the range of 30 to 70. The best results will most often be obtained when the hardness is in the range of 45 to 65.
The thickness of the surface layer lA need not be uniform over the entire surface of the cover, but at least about 70%, and preferably more than 80% of the surface area should be not less than 0.5 mm thick.
While there is no particular upper limit for the thickness of the layer lA, it should not exceed 10 mm from the points of view of economy, sense of softness, function of the cover in use and processing/molding efficiency.
Many of the materials suitable for the layer lA
may be foamed up to about three (3) times their solid volume for greater softness and reduced weight.
Materials suitable for the core layer lB include the following: -olefin homopolymers; copolymers of ethylene, propylene, etc. (olefin copolymers);
polycarbonates; impact resistant polystyrene; AS
polymers; and olefin-based rubbers, such as EPM, EPDM
and ethylene, butene-l copolymer rubber. These and other polymers may be used alone or blended to attain the desired properties. As is conventional, the material of the core layer lB may have incorporated i284 therein various fillers (for example, glass fibers, talc, calcium carbonate, silica, or mica), pigments, stabilizers and the like.
Among the polymeric materials mentioned above, high density polyethylene, polypropylene, propylene-ethylene block and random copolymers, and olefin-based rubbers are particularly desirable; of these polypropylene, propylene-ethylene block copolymers and high density polyethylene are preferred, because they combine well with materials suitable for the external surface layer lA (e.g., the olefin- and styrene-based elastomers) and have stable properties over a wide range of temperatures.
Good results have been obtained with a blend of a propylene-ethylene block copolymer and an olefin-based rubber (ethylene-propylene rubber). The amount of olefin-based rubber used in the material for the core layer lB should not, however, exceed 60% by weight.
Greater amounts cause problems in molding/processing and in mold maintenance.
If the material of the core layer lB of the air bag cover has a bending elastic modulus of less than 1000 kg/cm2 or is softer than the material of the surface layer lA, the cover will not maintain its original shape and can be deformed easily. On the other hand the bending elastic modulus of the core layer material should not exceed 30,000 kg/cm2 in order to provide a sense of softness in the cover as a whole (i.e., enable moderate deformation under contact by the vehicle occupant) and prevent the possiblity of breakage in an unintended manner when the air bag inflates at extremely low temperatures.
Advantageously, the bending elastic modulus of the core layer material should be in the range of 1,500 kg/cm2 to 11,000 kg/cm2 and, preferably, from 2,000 kg/cm2 to 7,000 kg/cm2. Some materials may have a bending elastic modulus within a desirable range but may still 2~6Z84 g be unsatisfactory due to, for example, large variations in properties with temperature changes or low impact strength.
There is no special limitation on the thickness of the core layer lB, but it should generally be about 1-3 mm.
As mentioned above, the core portion lB is provided with zones of weakness which enable the core lB to break easily when the air bag begins inflating.
Those zones may be rows of perforations lC, notches, or the like. The positions and extents of the weakened zones may vary in air bag covers according to the invention and can be designed taking into account such factors as the shape and strength of the cover.
Covers according to the invention can be manufactured by various conventional molding/processing methods for thermoplastic materials. Insert injection molding is highly suitable. In the insert injection molding method, the core portion is molded in one mold and then placed in another mold in which some space is left for the surface layer. The surface layer is injection-molded in the second mold. Also suitable is the double injection method in which the core portion is molded, the cavity mold is separated from the core portion, a new cavity mold having a space for the surface layer is placed over the core portion without taking the core portion out of the mold, and the surface layer is injection-molded.
The weakened zones of the core portion can be molded into the core portion in the mold or can be separately formed in it after it is molded.
The air bag cover can be coated with decorative colors in order to match the vehicle interior and improve the external appearance of the cover. Coating the surface layer lA is also desirable from the standpoint of protecting it from damage.

2~

The air bag cover according to the present invention does not cause the vehicle occupant any discomfort when his body contacts it since its relatively hard core portion is covered with the relatively soft surface layer. Because the core portion is hard, however, the cover resists deformation or damage from the usual external forces imposed on it.
When the air bag cover breaks along the weakened zones of the core portion upon inflation of the air bag, the broken pieces of the cover do not separate from the support and scatter around because the core layer is securely adhered to the soft surface layer.
Covers according to the present invention do not break in unintended ways (and pieces of the cover do not separate from the support) within a temperature range of -40C to 80C. Even though the cover layer tears along the lines of weakness of the core, it is less frangible than the core layer and less prone to rupture in an unintended manner. Therefore, the cover layer keeps the core layer pieces from being separated from the air bag support.

Examples and Comparative Examples The examples of the invention given in Table I are merely illustrative and are not intended to limit the scope of the invention. The comparative examples (Table II) exhibit some of the deficiences in the characteristics of covers that do not embody the invention.
In examples 1 to 11 and comparative examples 1 to 9, a core portion (1.0 - 3.0 mm thick) provided with slits (each about 0.7 mm long, 29 slits altogether) was injection-molded with a core material, as described below, using an in-line screw, two-color injection molding machine and a mold-clamping force of 350 tons, and then the surface layer injection-molded in the prescribed thickness over the core portion. Thus the air bag cover 1 shown in Fig. 1 was obtained.
In examples 3 and 10, the surface layer was foamed. Foam molding was carried out by blending 5 parts of a CO2-based foaming agent (Master Batch Fine Blow S20N, Mitsubishi Petrochemical Co., Ltd.) for each 100 parts of the surface material.
In examples 4 and 11, the surface layer was coated. After the cover was molded, the surface layer was wiped with isopropyl alcohol, a primer tSakai Chemical Co., Ltd., MEX5440 and methylethylketone at a 1:1 ratio) was applied to a thickness of 7-10 ~m by spraying and dried for 10 minutes at room temperature, and then a urethane top coat (Sakai Chemical Co., Ltd., MEX-6047: hardening agent F-3: thinner 58u =
100:10:50) was sprayed to a thickness of 20-25 ~m and dried for 10 minutes at room temperature. The cover was baked at 80C for 30-45 minutes.
The materials used in the examples of Table 1 are as follows:

PP-l: Propylene-ethylene block copolymer resin (BC-8, Mitsubishi Petrochemical) MFR (230C, 2.16 kg) = 1.8g/10 min (the melt Flow Rates set forth herein were determined by the procedures of ASTM D 1238) Bending elastic modulus = 11000 kg/cm2 JIS-A hardness = 100 PP-2: A 60/40 (weight ~) blend of propylene-ethylene block copolymer resin (BC-4, Mitsubishi Petrochemical) and ethylene-propylene rubber (EPO7p, Japan Synthetic Rubber) BC-4: MFR (230C, 2.16kg) = 6.5g/10 min Bending elastic modulus =11600 kg/cm2 EPO7p: ML (100C) = 70 Propylene content = 27%

20C~6284 Blend: Bending elastic modulus = 4000 kg/cm2 JIS-A hardness = 99 PP-3: A 50/50 blend of propylene-ethylene block copolymer resin and ethylene-propylene rubber (BC4, Mitsubishi Petrochemical Co., Ltd. and EPO7p, Japan Synthetic Rubber Co., Ltd.) BC4: MFR (230C, 2.16kg) = 6.5g/10 min Bending elastic modulus = 11,600kg/cm2 EPO7p: ML (100C) = 70 Propylene content = 27%
Blended product: bending elastic modulus =
2000kg/cm2 JIS-A hardness: 97 PP-4: Polyethylene (MA-4, Mitsubishi Petrochemical) MFR = Sg/10 min Bending elastic modulus = 12,000 kg/cm2 JIS-A hardness =100 PP-5: 30/70 blend of propylene-ethylene block copolymer resin (BC-4, Mitsubishi Petrochemical) and ethylene-propylene rubber (EPO7p, Japan Synthetic Rubber) Blended product:
Bending elastic modulus = 500 kg/cm2 JIS-A hardness = 86 EVA: Ethylene-acetic acid vinyl copolymer (V601S, Mitsubishi Petrochemical) MFR (190C. 2.16kg) = 15g/10 min Bending elastic modulus = 400 kg/cm2 JIS-A hardness = 82 Z~)06~

PE-l: Polyethylene resin made by the low pressure method (JX-10, Mitsubishi Petrochemical) MFR (190C, 2.16kg) = 20g/10 min Bending elastic modulus = 9000kg/cm2 JIS-A hardness = 100 PE-2: A 40/60 blend of linear low-density polyethylene resin and ethylene-propylene rubber (UJ280, Mitsubishi Petrochemical, and EP07p, Japan Synthetic Rubber) UJ280: MFR ( l90aC~ 2.16kg) = 30g/lOmin Bending elastic modulus = 2600kg/cm2 Blended product: bending elastic modulus =
400kg/cm2 JIS-A hardenss = 82 TPO-l: Olefin-based thermoplastic elastomer (Thermolan 3980, Mitsubishi Petrochemical) JIS-A hardness = 93 TPO-2: Olefin-based thermoplastic elastomer (Thermolan 3650, Mitsubishi Petrochemical); 10% by weight rubber softener (pw380, Idemitsu Kosan) JIS-A hardness = 65 TPS-l: Styrene-based thermoplastic elastomer (Rubbulon SJ4400, Mitsubishi Petrochemical); 10% pw380 JIS-A hardness = 45 TPS-2: Styrene-based thermoplastic elastomer (T-320, Mitsubishi Petrochemical) JIS-A hardness = 15 TPS-3: The material was made by blending 100 parts of the following four ingredients (1) SEBS-l, (2) SPX9400, (3) PIB-l and (4) OIL at a mixing ratio of 35/15/40/10 (wt%) with 0.2 parts of Irganox Z0C~6Z84 1010 (Ciba Giegy) as a stabilizer and 0.5 parts of carbon black, and mixing them at 200C using a double-shaft extruder.
JIS-A hardness = 55.
(1) The hydrogenated derivative of styrene-butadiene block copolymer (SEBS-l, Shell Chemical "Kraton"): Brookfield viscosity 20wt% (toluene solution 2000cps, 25C) (2) Propylene-ethylene block copolymer resin (SPX9400, Mitsubishi Petrochemical); MFR (230C, 2.16kg) = 69/10 min; bending elastic modulus =
4500kg/cm (3) Polyisobutylene (PIB-l) (Tetrax 3T, Japan Petrochemical); viscometric average molecular weight = 30000.

(4) Paraffin-based rubber softener (OIL) (pw380, Idemitsu Kosan); 40C kinetic viscosity =
380cst.

TPS-4: Prepared by the same method as TPS-3 but with the following composition.
(1) SEBS-1/(2) SPX9400/(3) PIB-1/(4) OIL in the ratio 35/15/30/20 (wt%); JIS-A hardness = 45 TPS-5: Prepared by the same method as TPS-3 and at the following composition using the hydrogenated derivative of styrene-butadiene block copolymer.
(1) SEBS-2/ (2)SPX 9400/ (3) PIB-l/ (4) OIL in the ratio 45/15/30/10 (wt%) JIS-A hardness = 68 SEBS-2 (Shell Chemical "Kraton") has a Brookfield viscosity of 20wt% (toluene solution 1500cps, 25C) Z~ 8~

TPS-6: Prepared by the same method as TPS-3, SEBS-l/SPX 9400/OIL in the ratio 35/5/60 (wt%);
JIS-A hardness = 15 TPS-7: Prepared by the same method as TPS-3 with the followin~ composition.
SEBS-l/BC-4/OIL/Calcium carbonate in the ratio 24/9/37/30 (wt%);
JIS-A hardness = 55 (For BC-4, see PP-2 above.) TPO-3: Olefin based thermoplastic elastomer (Thermolan 3600B, Mitsubishi Petrochemical) JIS-A hardness = 70 TPO-4: Olefin based thermoplastic elastomer (Thermolan 3920B, Mitsubishi Petrochemical) JIS-A hardness = 93 ZQ0~84~

In comparative example lO, an air bag cover consisting of a surface layer made of a high-density urethane foam and a core portion made of low-density urethane foam was made and evaluated. The core portion was molded by the RIM method at a low-foaming density and cured and then placed in a mold for forming the surface layer by insert injection molding. Freon gas was used as the foaming agent to foam the surface layer. This method required carrying out the curing process twice, thereby reducing the production rate.
In comparative example 11, an air bag cover provided with a reinforcing net was made and evaluated.
A woven net of polyester thread was cut so as to provide gaps corresponding to the zones of weakness of the cover. The net was inserted into a mold and the cover molded by the RIM molding method. Freon gas was used as a foaming agent. The cover was removed from the mold and cured at 100C for 30 minutes. It was difficult to form a good skin layer with the net inserted.
The materials of the core layer and surface layer, the JIS-A hardnesses of the materials and the bending eiastic modulus of the core layer material used in the examples and the comparative examples are set forth in Table I and Table II below.

2Q062~34 Table I
(Examples of the Invention) Exam. Core Layer Surface Layer Bend Elas2 HardnessHardness No. Mat'l Mod-k~/cm (JIS-A) Mat'l (JIS-A) 1 PP-l 11000 100 TPS-l 45 7 PE-l 9000 100 TPS-3 55 2006~84 Table II
(Comparative Examples) Exam.Core Layer Surface Layer Bend Elas HardnessHardness No. Mat'l Mod-kg/cm2 (JIS-A) Mat'l (JIS-A~

3 PP-2 4000 99 TPO-l 93 4 PE-2 400 82~ TPS-3 55 10 Urethane RIM foamed - without net 11 Urethane RIM foamed - with net ~006284 All of the air covers listed in Tables I and II
were tested by the following procedures.

(1) Sense of softness Either an air bag assembly composed of the air bag 2, the cover 1, retainers 4 and 5 and an inflator 3 (see Fig. 1) or a cover 1 alone was left in an environment at a temperature of -20C until the sample reached the ambient temperature, and then touched by the hands of 10 persons to evaluate its softness. The softness was rated as satisfactory when all 10 persons felt it as soft, as unsatisfactory when 8 or 9 of the 10 felt it as soft and as poor when less than 8 of the 10 felt it as soft. The same evaluation was made on each cover at a temperature of 80C.
(2) Shape maintainability Either an air bag assembly according to Fig. 1 or a cover 1 alone was held at a temperature of 80 -110C for many hours (less than 1000 hours) or in 10 heat cycles varying from -40C to 100C per cycle, and the deformation of the cover during and after the test was observed. The covers with little deformation were evaluated as satisfactory and those with extensive deformation were evaluated as poor.
(3) Low Temperature Operation Test The air bag assembly was attached to a steering wheel and allowed to attain an ambient temperature (-20C in the case of examples 1 to 5 and comparative examples 1 to 3 and -40C in the case of the remaining examples and comparative examples). The operation test was made less than one minute later. If the cover broke and scattered, broke in an unintended manner and caused the air bag to tear, or the cover otherwise operated abnormally, it was evaluated as poor. If the cover operated normally, it was evaluated as satisfactory.

2()06284 (4) Productivity Twenty covers were continuously manufactured, their external appearance, dimensions and weight were inspected, and the following evaluations assigned: all 20 covers were found acceptable: satisfactory; less than all but more than 90% of them acceptable:
unsatisfactory; less than 90% of them acceptable:
poor.

(5) Durability Test Covers according to examples 5 to 11 and comparative examples 4 to 11 were aged by a Geer-type heat aging tester at a temperature of 110C for 500 hours. They were then subjected to a low temperature operation test (as in 3 above) at a temperature of -40C and were also compared for appearance and shape retention. Only covers that operated normally were considered satisfactory. Any covers that showed deformation, bleeding of softener in the core layer or other physical or appearance changes were judged unsatisfactory.
All air bag covers according to the present invention (Examples 1 to 11) provided very good results in the evaluations of sense of softness, shape maintainability, operation at low temperature, durability and manufacturing productivity.
The comparative examples all exhibited one or more deficiencies, as set forth in Table III immediately below.

Z0~6Z84 Table III
(Deficiencies of Comparative Examples) No. Deficiency 1 Poor shape maintainability 5 2 Unsatisfactory productivity 3 Poor sense of softness 4 Poor shape maintainability Poor durability and unsatisfactory productivity 10 6 Poor sense of softness 7 Poor durability 8 Poor operation and durability and unsatisfactory sense of softness 9 Poor shape maintainability and productivity and unsatisfactory softness Unsatisfactory sense of softness and poor poor operation at low temperature 11 Unsatisfactory sense of softness and poor productivity There is, therefore, provided by the present invention an air bag cover that has a soft surface layer so that if the vehicle occupant contacts it, it does not feel uncomfortable. Furthermore, since the core portion is relatively hard, the cover maintains its shape very well and is highly durable. When the air bag inflates and breaks the cover along the weakened zones, the soft surface layer can reliably prevent the scattering of the broken core pieces. The cover can be manufactured efficiently by conventional molding methods, such as two-color injection molding, simply and with accuracy at a high yield rate with few rejects, thus enabling the production cost to be greatly reduced.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A cover for housing a folded vehicle air bag, the cover having weakened zones that enable it to break easily when the air bag inflates, characterized in that the cover has an external surface layer formed of a thermoplastic polymeric material having a Type A hardness of from about 20 to about 90 as determined by Japanese Industrial Standard K6301-1975 and a core layer formed of a thermoplastic polymeric material having a modulus in elasticity in flexure of not less than about 1000 kg/cm2 as determined in accordance with Japanese Industrial Standard K7203-1982 and a hardness greater than that of the surface layer, and in that the weakened zones are formed in the core layer.

2. An air bag cover according to claim 1 and further characterized in that the thermoplastic polymeric material of the external surface layer contains a predominant amount of a member of the group consisting of olefin-based elastomers, styrene-based elastomers, vinyl-chloride elastomers, soft polyvinyl chloride, and combinations thereof.

3. An air bag cover according to claim 2 and further characterized in that the olefin-based elastomer is selected from the group consisting of EPM
synthetic rubber, EPDM synthetic rubber, ethylene-butene-1 copolymer synthetic rubber, polypropylene, polyethylene, polyisobutylene, and combinations thereof.

4. An air bag cover according to claim 2 and further characterized in that the styrene-based elastomer is selected from the group consisting of block copolymers of monovinyl aromatic hydrocarbon polymer blocks and conjugate diene polymer blocks, hydrogenated derivatives of block copolymers of monovinyl aromatic hydrocarbon polymer blocks and conjugate diene polymer blocks, hydrogenated derivatives of block copolymers of styrene polymeric blocks and butadiene polymer blocks, and hydrogenated derivatives of block copolymers of styrene polymer blocks and isoprene polymer blocks.

5. An air bag cover according to claim 3 or claim 4 and further characterized in that the material of the external layer contains a hydrocarbon-based rubber softener in an amount of up to 30% by weight.

6. An air bag cover according to claim 1 and further characterized in that thermoplastic polymeric material of the core layer contains a predominant amount of a member of the group consisting of high-density polyethylene, polypropylene, block copolymers of propylene and ethylene, random copolymers of propylene and ethylene, olefin-based synthetic rubbers, and combinations thereof.

7. An air bag cover according to claim 6 and further characterized in that the material of the core layer contains an olefin-based synthetic rubber in an amount not exceeding 60% by weight.

8. An air bag cover according to claim 6 and further characterized in that the material of the core layer is a blend of a block copolymer of propylene and ethylene and an olefin-based synthetic rubber and in that the amount of the olefin-based synthetic rubber in the blend does not exceed 60%
by weight.