Abstract: A method is disclosed for forming a reinforced plastic skin for an automobile interior trim structure. The method includes the steps of supplying a plastic material onto a mold surface, heating the plastic material to fuse it into a unitary layer, embedding a reinforcing material into the layer, and cooling the plastic and reinforcing materials. The method can be used to reinforce an air bag door cover by incorporating a tear seam into the plastic layer and embedding the reinforcing material into the layer such that it surrounds the tear seam. The reinforcing material aids in rupturing of the cover along the designated tear seam during deployment of the air bag. Also disclosed is an air bag door cover formed in accordance with the disclosed method.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as a predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: Spherical particles having a diameter between 0.007" and 0.040" are formed from melt extruded thermoplastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040" that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermoplastic, plasticizers (if necessary) and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle. The microspheres may then be distributed as predetermined charge of such microspheres against the heated casting surface to melt the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: A process for producing a reinforced plastic motor vehicle bumper includes the steps of placing a woven roving (17) on a center section of a preform screen (10) that is retained by a vacuum draw from a suction fan (16). Chopped glass fibers (20) and a curable binder are sprayed onto the preform screen and woven roving. A second layer (22) of woven roving is placed onto the center section of chopped glass and first layer (17) of woven roving. Either the excess trim (39) is trimmed by a cutting die (50) before the preform is cured or the die is first cured and then the excess trim is trimmed by a cutter using a plastic base (35) in the screen that circumscribes the contoured section of the preform screen.

Abstract: A covered article such as an automotive trim panel comprises a substrate having a front surface to be covered, a back surface and a plurality of holes extending through it for vacuum drawing a trim cover stock against the front surface. The substrate has sets of parallel saw-tooth holder grooves in a peripheral margin of the back surface adjacent to an edge of the substrate for mechanically interlocking with marginal portions of trim cover stock and transverse manifold grooves that communicate with the holder grooves. An adhesive is applied to the front surface and the peripheral margin and the substrate is supported on a vacuum buck so that the peripheral margin overhangs the buck and the manifold grooves communicate with a vacuum source of the buck.

Abstract: A method is provided for making a lightweight composite panel in which an outer skin is developed by spraying a heat curable reactive urethane formulation onto a contoured heated surface of a mold cavity of a press mold and maintained thereon in a semi-cured state. A substrate-forming foam layer impregnated with a hardening compound is positioned against a second foam layer and the layers in turn laid over the semi-cured urethane skin. The foam layers are urged together within the mold under heat and pressure at a temperature sufficient to accelerate activating of the hardening compound to render the substrate-forming foam layer relatively stiff, hard and self-supporting and less compressible than that of the second foam layer, and to bond the foam layers to one another at their interface, while forcing the semi-cured skin material into interstices of the second foam layer and thereafter curing the skin producing a bond between the skin and the second foam layer.

Abstract: An impact resistent flexible grille is located in an impact zone at a front end of an automobile having a grille support structure and an energy absorbing bumper. The flexible grille is rigidly fastened to the grille support structure and the bumper by rigid attachments that are located so that the flexible grille flexes to avoid damage when the front bumper collapses rearwardly responsive to a front end impact. Elastomeric tethers connect deflected portions of the flexible grille to the grille support structure to guide them back to their original position when the bumper returns to its original position. In one arrangement, the rigid attachments are located along a vertical centerline of the flexible grille and an elastomeric tether connects each upper corner of the flexible grille to the grille support structure.

Abstract: A door trim panel component that has a nominal thickness includes an arm rest that has a die locked pocket for opening the door. The die locked pocket has a wall that is substantially thicker than the nominal thickness of the trim panel component to provide a comfortable hand grip. The door trim panel is molded with the aid of a preformed core block that is embedded in the hand grip to reduce the effective thickness of the hand grip during the molding process. The preformed core block is configured with a stand-off feature that facilitates molding and demolding the door trim panel.

Abstract: A method and apparatus is disclosed for forming a cover for an air bag deployment opening, the cover having a tear seam defined by a reduction in thickness of the cover. The cover can be formed as an unitary part of an outer skin layer for an automobile interior trim structure. The apparatus includes a thin shell having an inner surface upon which a thermoplastic material is cast to form the outer skin. A multiplicity of pins are disposed on and extend away from a backside thereof to transfer heat to the inner surface. The density of the pins is reduced on the portion of the backside of the shell proximate the portion of the inner surface upon which the tear seam of the outer skin is to be formed. The shell can be heated or cooled by using a plurality of nozzles to impinge heated or cooled air onto predetermined locations of the backside. A cover and tear seam construction is also disclosed.

Abstract: A method of simultaneously vacuum forming a plastic article and integrally joining a device thereto is disclosed wherein a lock defining surface is formed on an anchoring end of the device, a heat activated adhesive is applied to the lock defining surface, and air is drawn through vacuum holes in the mold surface that defines the shape of the article and is also drawn through vacuum holes in the lock defining surface to draw a heated sheet of thermoplastic material onto the mold surface and also into interlocking relationship with the lock defining surface to form the article and to mechanically interlock and adhere the device to the formed article.

Abstract: An interior trim panel for a motor vehicle has an opening for deployment of an air bag and a discrete air bag door that is attached to the interior trim panel covering the opening. The door includes a relatively rigid retainer that hinges the door to the trim panel so that it opens responsive to deployment of the air bag. An unhinged end of the door is held down by two tether tear straps that break away when the air bag is deployed.

Abstract: A covered article such as an automotive trim panel comprises a substrate having a front surface to be covered, a back surface and a plurality of holes extending through it for vacuum drawing a trim cover stock against the front surface. The substrate has sets of parallel saw-tooth holder grooves in a peripheral margin of the back surface adjacent to an edge of the substrate that is to be wrapped by the trim cover stock and transverse manifold grooves that communicate with the holder grooves. An adhesive is applied to the front surface and the peripheral margin and the substrate is supported on a vacuum buck so that the peripheral margin overhangs the buck and the manifold grooves communicate with a vacuum source of the buck. The trim cover stock is drawn against the front surface of the substrate and a marginal portion of the trim cover stock is simultaneously drawn against the peripheral margin of the back surface by vacuum to wrap the trim cover stock around the edge of the substrate.

Abstract: A cover for an air bag unit is disclosed having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and comprising a material having properties different than that of the cover material, Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon, A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that have the tear seam pattern, The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Abstract: An impact resistent flexible grille is located in an impact zone at a front end of an automobile having a grille support structure and an energy absorbing bumper. The flexible grille is rigidly fastened to the grille support structure and the bumper by rigid attachments that are located so that the flexible grille flexes to avoid damage when the front bumper collapses rearwardly responsive to a front end impact. Elastomeric tethers connect deflected portions of the flexible grille to the grille support structure to guide them back to their original position when the bumper returns to its original position. In one arrangement, the rigid attachments are located along a vertical centerline of the flexible grille and an elastomeric tether connects each upper corner of the flexible grille to the grille support structure.

Abstract: A motor vehicle is provided with an air bag system having a singular air bag that deploys downward from the ceiling to cushion the front and both sides of both the driver and a front seat passenger from over their head and to at least their shoulders to prevent their impacting with upper interior portions of the vehicle and with each other in a collision. The air bag includes an elongated front section that extends transverse of the vehicle along the front of the seats, elongated side sections that extend rearwardly from the front section along the outer side of the respective seats, and an elongated intermediate section that extends rearwardly from the front section between the seats.

Abstract: A process for manufacturing a metallized part comprises the following steps. A part is provided made from a substrate material selected from the group consisting of thermoplastic urethane (TPU), TPU alloys, polyester alloys, nylon, thermoplastic olefins (TPO) and aluminum. A single protective layer (combined primer/basecoat) is spray deposited, flashed and cured over the substrate. Over the combined primer/basecoat layer, a layer of corrosion prone metal is vacuum deposited to form a discontinuous film covering the combined primer/basecoat layer. A layer of clear resinous protective dielectric topcoat is spray deposited and cured to completely cover the layer of vacuum deposited corrosion prone metal material and fill channels formed in the discontinuous film layer.

Abstract: A cover for an air bag unit having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and including a material having properties different than that of the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that has the tear seam pattern. The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Abstract: A process for manufacturing a metallized part using the island coating method, including spray depositing a primer layer, basecoat layer, or combined primer/basecoat layer. Each layer contains an increased amount of film forming polymer by using liquid CO.sub.2 as a supplemental carrier along with a reduced amount of organic solvent carrier thereby reducing waste disposal costs and environmental concerns. Further, this modified island coating system can be used to deposit layers of 1.5 to 2.0 mils thick and maintain the aesthetic properties of the metallizing island coating system at a reduced cost and with minimal variability among parts.

Abstract: A steering wheel (12) incorporates an air bag unit (22). The air bag unit has a cover door (30) with a transducer (38) molded in a deformable front wall (35) of the cover door. The transducer can be a force sensitive resistor (38) which is operably connected to an electrical circuit (42) that actuates a horn (44) when the circuit senses a change in the resistance of force sensitive resistor (38). The force sensitive resistor (38) produces a suitable change in resistance when hand pressure is exerted on the front wall (35).

Abstract: An automobile door having an interior trim panel with air flow control openings at a bottom edge thereof. The air flow control openings direct outside air entering the normal drain holes in the door onto the floor of the passenger compartment to thereby prevent this air from entering the passenger compartment through partially sealed openings in the trim panel in which a door release handle and power door and power window switches are received.