Passenger airbag module using an essentially unitary cover

An airbag cover assembly having an integral airbag deployment door incorporated in a vehicle panel for deployment of an airbag from an airbag module positioned behind said panel and deployment door, comprising:

• a panel front surface facing an interior of a vehicle compartment,
• a panel rear surface substrate,
• a foam core positioned between and separating said panel front surface from said panel rear surface substrate,
• said panel rear surface substrate having a dropped lip extending from an end thereof,
• a deployment door defined in said panel and hinged along one side thereon in said panel,
• said deployment door comprises a door front surface, a door rear surface substrate and a foam core positioned between and separating said door front surface from said door rear surface substrate and a complete discontinuity existing between the foam core of the door and the foam core of the adjacent portions of the panel and between the door rear surface substrate and the adjacent portions of the panel rear surface substrate whereby the foam core of the door is completely separated from the foam core of said panel except at the hinged side of the door,
• said deployment door positioned in said panel on said dropped lip of said panel rear surface substrate whereby said deployment door and adjacent portions of said panel extend side by side at the same level and whereby the deployment door can be opened without ripping any part of said foam cores, thereby preventing foam core debris from being emitted through an open deployment door on deployment of said airbag.