Thermoplastic air bag cover assembly having a switch and method of making same

A thermoplastic air bag cover assembly comprising:

• a thermoplastic front panel having inner and outer surfaces;
• a thermoplastic back panel mounted on the inner surface of the front panel, the back panel also having inner and outer surfaces, the inner surfaces of the front and back panels defining first and second channels and a switch pocket between the channels;
• a switch disposed in the switch pocket so that pressure on the outer surface of the front panel actuates the switch;
• and
• a weld disposed within each of the channels, each weld being defined by a thermoplastic electromagnetic material which, when melted and placed under pressure, is caused to conform to the configuration of its respective channel to bond to and secure together surface layers of the front and back panels at its respective channel by polymer-to-polymer linkages.

A method of manufacturing a thermoplastic air bag cover assembly including a thermoplastic front panel, a thermoplastic back panel, and a switch, the method comprising the steps of:

• positioning the front and back panels so that inner surfaces of the panels define at least one channel and a switch pocket therebetween;
• positioning a thermoplastic electromagnetic material in the at least one channel;
• positioning the switch in the switch pocket;
• establishing a electromagnetic field about the positioned thermoplastic electromagnetic material for a time sufficient to melt the material to obtain molten material within the at least one channel, the molten material melting surface layers of the front and back panels defining the at least one channel;
• forcing the surface layers together to cause the molten material to flow and be contained within the at least one channel;
• and
• allowing the molten material and the surface layers to cool wherein the molten material is fused with the surface layers causing polymer-to-polymer linkages therebetween.