Abstract: A method and system of manufacturing an air bag cover assembly utilizing infrared radiation is disclosed. The assembly includes a front panel, a back plate, a switch and infrared-absorbing material. Initially, the front panel and the back plate are positioned so that inner surfaces of the front panel and the back plate define a switch pocket therebetween. Then the switch is positioned in the switch pocket. Thereafter, infrared radiation is directed at the infrared-absorbing material for a time sufficient to heat the infrared-absorbing material to a desired temperature. The amount of heat applied to the infrared-absorbing material by the infrared radiation is controlled by a controller. Finally, the heated material cools to fixedly secures the back plate to the front panel. The heated material may be forced to flow prior to cooling.

Abstract: A molded plastic component having enhanced surface finish is molded within a mold having at least one metal base, a mold cavity, and at least one self-lubricating surface layer which defines the plastic component within the mold cavity. The self-lubricating surface layer includes a porous metallic skin integrally connected to and extending from an interior surface of the at least one metal base and lubricating particles disposed on the skin and in pores of the skin. The lubricating particles are bonded together to form a sealed surface of the at least one self-lubricating surface layer such that the molded plastic component has the enhanced surface finish. The metallic skin includes a plurality of spaced, sinusoidally-shaped projections of autocatalytic nickel alloy. The lubricating particles are preferably submicron-sized particles of low friction fluoropolymers. The mold may be an injection mold, a compression mold, a blow mold or a vacuum mold.

Abstract: An air bag cover having a decorative badge secured thereto is made by injection molding a thermoplastic elastomeric body in an injection mold having a shape defining the air bag cover. Slots are formed at predetermined spaced locations extending through the air bag cover. The decorative badge has a plurality of tabs extending therefrom at predetermined spaced locations corresponding to the spaced locations of the slots formed in the air bag cover. The tabs are inserted through the slots at a front surface of the air bag cover and bent against a rear surface of the air bag cover to create a substantially constant load on the elastomeric body. The elastomeric body exerts an opposing reaction to the constant load so as to allow the decorative badge to be secured to the air bag cover.

Abstract: A removable hardtop including inner and outer roof panels made of molded fiber reinforced sheet molding compound. An integral roll bar is formed in the inner roof panel. A hold down clamp and bracket having horizontal, vertical and transverse flanges mounted on a horizontal edge, vertical surface and transverse surface of a B pillar of a vehicle. A method of molding the inner and outer roof panels and assembling component parts to the inner and outer roof panels is also disclosed.

Abstract: A mold for use in a gas-assisted injection molding system includes a gas pin assembly which can be readily removed from one mold half in an open position of a mold wherein a porous insert of the assembly can also be readily removed from the housing of the assembly for easy servicing. The housing of the assembly has an elongated aperture formed therethrough in communication with a gas passageway in the mold to permit the flow of gas therethrough. The porous insert is positioned in the aperture. The insert permits the flow of gas therethrough but prevents the passage of molten plastic therethrough. The assembly also includes a holding device preferably in the form of a set screw which has a gas hole formed completely therethrough to permit the flow of gas therethrough. The set screw is threadedly secured within the housing to hold the insert stationary within the aperture and to permit ready removal of the insert from the housing after the set screw has been removed from the housing.

Abstract: A cigar holder for a vehicle is formed with one portion to support a cigar and another portion of non-heat conducting and weather resistant material to protect the vehicle from the heat of the cigar and the cigar holder from the deleterious effects of the weather. The cigar holder is attachable to the vehicle by a suction cup which is concealed by an insert which is selectable to give the cigar holder different appearances.

Abstract: An automotive air bag cover is provided having a decorative applique preform bonded thereto completely about a pair of flap portions of a front panel of the cover. The air bag cover is manufactured from plastic and the front panel is adapted to enclose an uninflated automotive air bag. The front panel includes inner and outer surfaces. Side panels are further provided and are connected to and extend rearwardly from the front panel. The decorative applique preform is bonded to the entire outer surface of the front panel except for the flap portions. Seams are provided for permitting the air bag to inflate and exit the front panel. The decorative applique preform is bonded to the front panel adjacent the seams in a non-overlapping fashion such that the decorative applique preform does not interfere with exit or inflation of the air bag.

Abstract: An air bag cover assembly is provided. The assembly includes a front panel having inner and outer surfaces and a switch module attached to the inner surface of the front panel. The switch module includes a front plate and a back plate attached to and spaced apart from the front plate to define a switch pocket therebetween and a switch disposed in the switch pocket. The front plate has a plurality of spaced ribs integrally formed at and projecting from an outer surface of the front plate towards the inner surface of the front panel. Distal ends of the ribs are shaped to substantially conform to the inner surface of the front panel so that pressure on the outer surface of the front panel at a switch activation area is transmitted by the ribs to activate the switch.

Abstract: Method and system are provided for building a data model of a physical part in a data format useful for reproduction of the part. The system preferably includes a Moire interferometry system including a camera mounted on a portable coordinate measuring system (CMM) to obtain high density data scans in the form of 3-D point data from different positions and orientations of the interferometry system relative to the part. The CMM provides position data to enable an engineering workstation to convert the data scans obtained in multiple local coordinate systems into a single global coordinate system. The engineering workstation then integrates the data scans in the global coordinate system and joins the point data to form a polygonal structure corresponding to multiple continuous surfaces of the physical part. From this data, a tool path can be generated to cut a reproduction of the part or a mold for molding the reproduction.

Abstract: A mold for use in a gas-assisted injection molding system having a nozzle includes a runner shut-off subsystem which prevents pressurized gas from flowing through the runner and into the nozzle. A pair of pins are preferably mounted on a plate to move therewith between extended and retracted positions of the plate. The pins are slidably fit within one mold half of the mold to move within the runner between extended gas-blocking positions to block the flow of pressurized gas through the runner and into the nozzle and retracted positions to allow the flow of molten plastic from the nozzle, through the runner, through a gate, and into an article-defining cavity in a closed position of the mold. The runner shut-off subsystem includes a hydraulic cylinder for moving the plate and the pins relative to the mold half. Each of the pins has a free end portion which extends into another mold half of the mold where it is received and retained in its extended gas-blocking position.

Abstract: An air bag cover assembly is provided including a front panel adapted to overlie an undeployed air bag, an ornamental pad permanently fastened to the front panel within an outer recessed portion, and a membrane-type switch lying behind the rear inner surface of the pad in a switch location area defined by a plastic top plate and an ornament of the ornamental pad. In a first embodiment, the ornament is a plastic ornament integrally formed with the plastic top plate. In a second embodiment, the ornament is fixedly secured as a separate part to the plastic top plate. In the second embodiment, the plastic top plate is a thermoplastic elastomeric body having a front surface and a rear surface.

Abstract: A mold for use in a gas-assisted injection molding system includes a gas pin assembly which can be readily removed from one mold half in an open position of a mold wherein a porous insert of the assembly can also be readily removed from the housing of the assembly for easy servicing. The housing of the assembly has an elongated aperture formed therethrough in communication with a gas passageway in the mold to permit the flow of gas therethrough. The porous insert is positioned in the aperture. The insert permits the flow of gas therethrough but prevents the passage of molten plastic therethrough. The assembly also includes a holding device preferably in the form of a set screw which has a gas hole formed completely therethrough to permit the flow of gas therethrough. The set screw is threadedly secured within the housing to hold the insert stationary within the aperture and to permit ready removal of the insert from the housing after the set screw has been removed from the housing.

Abstract: A method and apparatus for making a thermoplastic air bag cover having a hidden tear seam. A molten thermoplastic is injected into a mold cavity of a mold having a shape defining the air bag cover. An insert having a shape defining the tear seam is extended into the mold cavity before the molten plastic completely solidifies. The resulting air bag cover is cooled to a temperature beneath the softening point of the plastic. The completed air bag cover is then removed from the mold. The thickness of the air bag cover at the tear seam is within a range of 0.2 to 0.4 millimeters.

Abstract: An air bag cover having a decorative badge secured thereto is made by injection molding a thermoplastic elastomeric body in an injection mold having a shape defining the air bag cover. Slots are formed at predetermined spaced locations extending through the air bag cover. The decorative badge has a plurality of tabs extending therefrom at predetermined spaced locations corresponding to the spaced locations of the slots formed in the air bag cover. The tabs are inserted through the slots at a front surface of the air bag cover and bent against a rear surface of the air bag cover to create a substantially constant load on the elastomeric body. The elastomeric body exerts an opposing reaction to the constant load so as to allow the decorative badge to be secured to the air bag cover.

Abstract: A mold for use in a gas-assisted injection molding system includes an ejector pin subsystem including a split pin which partially blocks the flow of molten plastic through a secondary runner, helps to eject solid plastic from the mold, and helps to define an article-defining cavity and the secondary runner in the mold. A first spill cavity is flow coupled by the secondary runner to the article-defining cavity. The split pin together with other ejector pins are mounted on an ejector plate to move therewith between extended and retracted positions. A second spill cavity is flow coupled by a tertiary runner to the first spill cavity if needed. The split pin, as well as the other ejector pins mounted on the ejector plate, eject plastic from the article-defining cavity, the spill cavities, and the secondary and tertiary runners in the extended position of the ejector plate.

Abstract: A mold for use in a gas-assisted injection molding system includes an ejector pin subsystem including a blocking pin assembly which not only blocks the flow of molten plastic through a secondary runner but also helps to eject solid plastic from the mold. The mold also includes an adjustable overflow pin assembly and a conically-shaped spill cavity flow-coupled by the secondary runner to an article-defining cavity of the mold. The blocking pin assembly together with the adjustable overflow pin assembly are mounted on an ejector plate to move therewith between extended and retracted positions of the ejector plate. The blocking pin assembly includes a blocking pin which is slidably fit within a mold half to move between an extended blocking position to block the flow of molten plastic through the secondary runner and a retracted position to allow the flow of molten plastic through the secondary runner and into the spill cavity.

Abstract: A method and apparatus for making a thermoplastic air bag cover having a visually perceptible tear seam formed by a controlled amount of plastic sinkage during an injection molding process. A molten thermoplastic is injected into a mold cavity of a mold having a shape defining the air bag cover. The mold includes first and second mold halves which form the interior and exterior surfaces of the air bag cover. The first mold half has an outwardly extending projection which cooperates with a smooth inner surface of the second mold half to form the tear seam design in the air bag cover which appears on the outer surface of the air bag cover. The tear seam design formed on the outer surface of the air bag cover is primarily formed because of the near right angles formed at the top edges of the outwardly extending projection which cause the outer surface of the air bag cover to sink to a limited controlled extent during cooling of the plastic beneath its softening point.

Abstract: A mold for use in a plastic injection molding system includes a venting pin assembly which can not only vent an article-defining cavity in the mold but can also eject a formed plastic article in an open position of the mold. A porous insert of the assembly permits air from the article-defining cavity to flow there-through while preventing the passage of molten plastic from the article-defining cavity in a closed position of the mold. A venting pin of the assembly in the form of a hollow ejector pin has an elongated aperture formed therethrough to permit the flow of air therethrough. The porous insert is positioned in the aperture at a gas hole formed through an end surface of the ejector pin. The insert and the gas hole are sized so that the insert and the end surface help to form a "Class A" surface on the article formed in the article-defining cavity.

Abstract: An air bag cover assembly includes a plastic cover section, a switch section, a backing section and a set of temporary fasteners for fastening the backing section to the cover section to maintain alignment of sets of holes formed in the cover section, the backing section and the fasteners, which aligned holes provide clearance for a set of permanent fasteners used to secure the air bag cover assembly to an air bag housing assembly. The temporary fasteners preferably take the form of a set of annular members which are integrally formed on a rearwardly extending member of the backing section and which provide a snap-in fastening of the rearwardly extending member to a side panel of the cover section. The rearwardly extending member of the backing section is attached to a back plate of the backing section in a living hinge-like fashion to facilitate deployment of an air bag.

Abstract: A stackable ashtray of rectangular shape is provided in a plastic container having notched walls for supporting cigarettes and outwardly extending channels for supporting cigars.