# US 5,344,183 A · Multi-layer air bag cover with filled reinforced vinyl > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,344,183 A - Document ID: US5344183A - Status: Granted - Kind: A - Application number: 08/062,239 - Filed: 1993-05-17 - Granted: 1994-09-06 - Earliest claimed: 1993-05-17 - Assignees: Davidson Textron Inc. - Inventors: Marie J. Hersman; Wayne C. Salsibury - Web page: https://patentgrep.com/patent/US5344183A ## CPC - B29C 37/0057: {Moulding single grooves or ribs, e.g. tear lines (folding lines B29C53/06)} - B29C 41/18: Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off - B29C 41/22: Making multilayered or multicoloured articles - B60R 21/2165: characterised by a tear line for defining a deployment opening - B29K 2027/06: PVC, i.e. polyvinylchloride - B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles - B29K 2105/16: Fillers - B29K 2105/26: Scrap {or recycled material} - B29L 2031/3038: {Air bag covers} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A reinforced vinyl shell comprises a two layer construction for covering air bag doors that open through the shell when an air bag is deployed. The reinforced vinyl shell includes a first layer of unreinforced vinyl and a second layer is fused to the first layer and is formed of a vinyl material mixed with reinforcing fibers. Such fibers are randomly dispersed in the vinyl and may be comprised of fillers, such as glass, recycled RIM, or recycled vinyl. Other thermoplastic castable materials may be used in place of the vinyl. ## Claims ### Claim 1 A method of making a cast thermoplastic reinforced shell, the method including the steps of: casting a first layer of unreinforced thermoplastic castable material as an outer decorative layer in a mold, casting a second layer of thermoplastic castable material and randomized reinforcing material mixed therein on the first layer, heating the mold and first and second layers to fuse the first and second layers to one another, and cooling and removing the formed thermoplastic reinforced shell comprising the first and second layers of thermoplastic with reinforcing material interspersed within said second layer. ### Claim 2 (depends on 1) A method as set forth in claim 1 further including mixing the thermoplastic castable material and reinforcing material with one another in a randomized manner prior to casting in the mold. ### Claim 3 (depends on 2) A method as set forth in claim 2 further including mixing glass fibers as the reinforcing material. ### Claim 4 (depends on 2) A method as set forth in claim 2 further including mixing thermoplastic castable material with the reinforcing material of the second layer as the same the thermoplastic castable material utilized in the first layer. ### Claim 5 (depends on 4) A method as set forth in claim 4 further including forming the thermoplastic reinforced shell as a portion of an instrument panel and air bag cover. ### Claim 6 (depends on 5) A method as set forth in claim 5 further including using vinyl as the thermoplastic castable material. ### Claim 7 A multi-layer shell comprising: a first layer of material including a thermoplastic castable material molded in a predetermined shape forming an outer decorative layer, a second layer of material fused to said first layer of material; said second layer of material including first particles of thermoplastic castable material and particles of randomized reinforcing material and said first and second particles fused to said first layer. ### Claim 8 (depends on 7) The multi-layer shell of claim 7 wherein said first particles of thermoplastic castable material are a mixture of virgin vinyl material and recycled vinyl material. ### Claim 9 (depends on 7) The reinforced shell as set forth in claim 7 wherein said second particles of randomized reinforcing material comprises glass fibers. ### Claim 10 (depends on 7) The multi-layer shell as set forth in claim 7 further comprising an exterior door of an air bag deployment system of a vehicle and a layer of foam interposed between said exterior door and said multi-layer shell; said second layer of material reducing ballooning of said multi-layer shell with respect to said layer of foam as said exterior door is deployed into an open position through said foam layer and said multi-layer shell. ### Claim 11 (depends on 9) The multi-layer shell as set forth in claim 9 further comprising an exterior door of an air bag deployment system of a vehicle and a layer of foam interposed between said exterior door and said multi-layer shell; said second layer of material reducing ballooning of said multi-layer shell with respect to said layer of foam as said exterior door is deployed into an open position through said foam layer and said multi-layer shell.