Airbag door for a vehicle interior panel and method of manufacturing the same

1. A vehicle interior panel for use over an airbag, comprising:

a substrate having an airbag door; and

a plurality of t-shaped stiffening ribs, each t-shaped stiffening rib of the plurality of t-shaped stiffening ribs having a cross portion and a main body portion, and wherein each t-shaped stiffening rib is spaced from and separately embedded in the airbag door of the substrate with respect to one or more other t-shaped stiffening ribs of the plurality of t-shaped stiffening ribs.

2. A vehicle interior panel for use over an airbag, comprising:

a substrate having an airbag door; and

a t-shaped stiffening rib, wherein the t-shaped stiffening rib is at least partially embedded in the airbag door of the substrate, and wherein the t-shaped stiffening rib has a height defined between the end surface and an impact facing surface, wherein the height of the t-shaped stiffening rib is 70-90%, inclusive, of a thickness of the airbag door.

3. The vehicle interior panel of claim 1 , wherein an end surface of each main body portion is coincident with an outboard surface of the airbag door.

4. The vehicle interior panel of claim 1 , wherein each cross portion includes two extension flanges that are oriented generally orthogonally with respect to the main body portion.

5. The vehicle interior panel of claim 4 , wherein each cross portion includes an impact facing surface formed by both extension flanges.

6. The vehicle interior panel of claim 5 , wherein each impact facing surface is oriented generally parallel to an inboard side of the airbag door.

7. The vehicle interior panel of claim 1 , wherein each t-shaped stiffening rib of the plurality of t-shaped stiffening ribs is wholly embedded within a thickness of the airbag door.

8. The vehicle interior panel of claim 1 , wherein each t-shaped stiffening rib of the plurality of t-shaped stiffening ribs has a primary length between a first side end and a second side end, wherein each primary length is oriented generally parallel to a hinge portion of the airbag door.

9. The vehicle interior panel of claim 1 , further comprising a second airbag door in the substrate and a deployment opening location that is situated at least partially between the airbag door and the second airbag door, wherein a distribution of the plurality of t-shaped stiffening ribs is symmetrical with respect to a portion of the deployment opening location that is situated between the airbag door and the second airbag door.

10. A method of manufacturing a vehicle interior panel for use over an airbag, the vehicle interior panel including a substrate having an airbag door, the method comprising the steps of:

injecting a first plastic material around a t-shaped stiffening rib made from a second plastic material, wherein the first plastic material is a thermoplastic elastomer and the second plastic material is polypropylene or acrylonitrile butadiene styrene (ABS); and

at least partially embedding the t-shaped stiffening rib into the airbag door of the substrate.

11. The method of claim 10 , wherein at least some bonding occurs between the airbag door of the substrate and the t-shaped stiffening rib during the injecting step.

12. The method of claim 10 , wherein the t-shaped stiffening rib includes a main body portion having an end surface, and a cross portion that intersects with the main body portion, wherein the end surface is not embedded in the airbag door of the substrate and the cross portion is wholly embedded in the airbag door of the substrate.

13. The method of claim 10 , wherein the injecting step includes injecting the first plastic material around a plurality of t-shaped stiffening ribs, each t-shaped stiffening rib of the plurality of t-shaped stiffening ribs having a cross portion and a main body portion, and wherein each t-shaped stiffening rib is spaced from and separately embedded in the airbag door of the substrate with respect to one or more other t-shaped stiffening ribs of the plurality of t-shaped stiffening ribs.