Abstract: A method of manufacturing a multi-layered plastic manifold (10) including molding an outer layer (22) of the manifold (10) about a blow molded core insert (20). The outer layer (22) is molded by either a thermoplastic injection molding process or a urethane casting process. While the outer layer (22) is being molded, the pressure and temperature within the core insert (20) are controlled to preserve the structural integrity of the core insert (20).

Abstract: An air compressor 10 for an air leveling suspension system of a motor vehicle is mounted on a vibration reducing bracket 12. The bracket includes a bottom panel section 16 that has a perforated metal grid 40 embedded therein. Side walls 18 extend to an open top 20. A first set of brass inserts 24 are embedded into a plurality of tiers 22 that are spaced between the closed bottom panel section 16 and open top 20 to mount the air compressor 10. A second set of brass inserts receive bolts 31 to mount the bracket to the chassis 14 of a motor vehicle.

Abstract: A liquid thermoset coating is described for application on and near surfaces of molded plastic parts where the resin rich phase has been disturbed or imperfectly formed. The coating has been found to be effective at minimizing paint pops and craters in subsequent finish coatings on said parts. Said paint pops and craters develop during heated cure cycles for the finish coatings. The coating which is applied to the heated part and subsequently cured is preferably an epoxy composition of low viscosity. The molded plastic parts are preferably fiber reinforced thermoset polyester parts with an in-mold coating to improve surface quality.

Abstract: A process for cutting hollow molded plastic parts uses two knife cuttings in sequence. A first knife blade (42) is pressed on an uncut hollow molded plastic part for cutting therethrough with a guillotine blade action to form an access hole (46, 48) in the plastic part (10). The plastic part (10) may be secured onto a clamp (34, 36) for the first guillotine blade action. An outer support clamp (50, 52) is then secured about the plastic part with an outer side of the support clamp being positioned in proximity to the finished cut edge (65) of a finished plastic part. A mandrel (54) is inserted into the access hole (46, 48) of the part. The inner end of the mandrel is axially spaced from the outer side of the support clamp to allow a thin knife blade therebetween. A thin knife blade (62, 64) then cuts off the rough edge (47) to provide a finished cut edge (65) in the plastic part axially interposed between the outer side of the support clamp and the inner mandrel.

Abstract: A process for forming a preform includes drawing a vacuum through a porous overform (16) from its outer surface toward its inner surface; providing retractable pins (32) that protrude through vertical extending sections (34) of the overform when in an extended position; depositing chopped fibers onto the outer surface of the overform such that the vertical extending sections of the overform have the fibers retained against sag by protruding sections (35) of the pins while said preform is formed; and retracting the pins from the vertical extending sections of the overflow in order to remove said preform from said overflow after cure. The invention is also directed to an apparatus for the use in manufacturing fibrous preforms that incorporates a porous overform (16) for receiving chopped fibers and binder material thereon and a plurality of pins (32) protruding through a vertically extending section (34) of the overform for engaging and supporting chopped fibers deposited onto the overform.

Abstract: An infant carrier (10) has an upper opening (32) that has a track (42) at each edge. A sliding door (40) is mounted in the track (42) for movement between an open and closed position. The door has mesh covered windows (43) that provide visibility to the infant and vision for the infant. The door is flexible in the longitudinal direction to expeditiously slide in the track which is contoured about the housing.

Abstract: An energy absorbing interior automotive trim part (36) has a shell (42) made from polypropylene sections (62), (68), and (69) divided via partitions (58) and (72) extending from the outer wall (44) of shell (42) and touching the passenger compartment facing wall (46). The shell (42) is blow molded with carpet (74), vinyls and other fabric materials (76) integrally molded to adhere directly to wall (46). After molding, interior section or partial section (62) is filled with a structurally engineered energy absorbing foam (64) to provide an energy absorbing structure which will compress a pre-determined distance while absorbing the compressive force applied.

Abstract: This invention relates to a method of sealing the porous surfaces that can be generated during the manufacturing and processing of molded plastic parts. Liquid thermoset coatings are applied to preheated parts and cured to create a barrier on the surface to gasses generated during heat curing of subsequently applied surface coatings. The liquid coating may be comprised of polyurethane forming components; those components in combination with unsaturated polyester resins; vinyl ester resin compositions; coatings derived from hydroxyl or carboxyl containing oligomers reacted with alkylated urea-formaldehyde, melamine-formaldehyde, and/or benzoquanamine-formaldehyde resins; and oligomers containing carboxyls reacted with triglycidyl isocyanurate.

Abstract: An interface for incorporation between an articulated arm robot and a cutting nozzle for cutting a circular opening in a workpiece. The interface includes apparatus for moving the cutting nozzle independently of the arm robot. The interface includes a first moving mechanism for moving the cutting device linearly to an offset position with respect to an axis extending through a center of the opening to be cut, and a second moving mechanism for moving the offset cutting nozzle in a circular path around the axis to cut the opening.

Abstract: Sheet molded compound articles which optionally can be in-mold coated have the edges and exterior margin surfaces thereof sealed with a water-free and solventless fine particle size powder coating. The coating thickness has a gradual and smooth transition from the sealed edge to the non powder coated exterior surface thereby eliminating the need for sanding. The desired method of application is by electrostatic spraying and the cured powder coating is free of pops.

Abstract: A handle (12) mounted to a support bracket (34) underlying a headliner (10) through two mounting devices (11). Each mounting device (11) includes a T-shaped end section (24) of a U-shaped spring metal strap (22) of the handle having a T-end that engages a T-shaped aperture in the support bracket (34). The body (20) of the handle includes a tab (23) that extends beyond end 51 of the body (20) and into the T-shaped aperture to abut an abutment shoulder (44) adjacent the T-shaped aperture in order to interlock with the T-shaped end section (24) of the strap. The tab (23) is removable from the aperture (40) and disengageable from the abutment shoulder (44) to allow the handle to be removable from the bracket (34).