Abstract: A pull strap handle (10) for an automotive interior is fully cushioned by forming a foamed resin cushion (20) that is fit around and over both faces of a strap (15) for the handle. A backing bar (30) is then positioned to extend over cushion (20) and be spaced from strap (15), and a resin cover (25) is wrapped over the cushion and over backing bar (30) so that edges of the cover overlap adjacent the backing bar. Then a dielectric bonding bar (31) presses the overlapping edges of cover (25) against the metal backing bar so that the cover edges are dielectrically bonded together in a seam that preferably has the same surface texture pattern as the rest of the cover material, so as to be inconspicuous. Then backing bar (30) is slid endwise out from under cover (25), to leave the seam (32) spaced from strap (15) by the thickness of cushion (20) which can extend all around and over both faces of the strap. Handle ( 10) is then completed by forming the strap and providing end anchorages, as is generally known.

Abstract: A retainer for a molded panel has a base 10 with a flat region 15 and projections 13 extending into the material of the molded panel to retain base 10 securely in place. Edge regions 12, extending away from the panel surface, interlock with a cap 11 located to straddle base 10 and have a central region 20 spaced from base 10 to receive and hold a fastener securing the cap, retainer and panel in place. Interchangeable caps 11, made in varying heights to span varying distances between a panel and its anchorage, can be mounted on universal base 10.

Abstract: A combination brake light and convenience light for use in the rear of an automotive vehicle is disclosed. A brake light 8 faces and illuminates through the rear window 4, and the convenience light 14 faces forward and downward over the shoulder of a rear seat occupant. A hinged cover 20 over the convenience light 14 serves three purposes: it esthetically covers the light when not in use; it prevents direct incidence of its light upon the driver's rear view mirror or the driver's line of sight; and it operates the on-off switch for the convenience light.

Abstract: A mounting fastener 2 which includes various combinations of base plate 30, mounting bracket 4, and fastener 18 is disclosed. The mounting bracket 4 is a formed wire bracket to provide the stand-off distance between a supporting structure and a mounted panel. Mounting bracket 4 has a pair of parallel feet 6 and a pair of parallel legs 8 extending upward from these feet and a yoke 10 joining the legs in a generally transverse plane (which may or may not be parallel with the feet 6) over the feet, yoke 10 defining a collar 14 into which fastener 18 is resiliently snapped. Opposed tips 16, one extending at the end of each foot 6, adapt mounting bracket 4 for resilient snap engagement to a panel member. Bracket 4 snaps into engagement in channels 38 and tip holes 40 of the base plate 30. A simpler form of bracket 50 is adapted to hang on a supporting structure, also effecting the spacing of the mounted panel from the supporting structure.

Abstract: An automotive panel bracket 10 is formed from a strip having a central fold line 22 forming a double-walled stand-off 15 between a pair of base portions 11 and 12 interconnected with an automotive panel 20. A pair of confronting semi-cylindrical grooves 17 and 18 in double walled stand-off 15 form a generally cylindrical pilot hole 16 guiding a fastener 25 that extends through panel 20, through pilot hole 16 in stand-off 15, and into an automotive body 30 to which panel 20 is secured.

Abstract: A resin cladding is extruded onto a base strip 10 that is assembled into a cushioned automotive pull strap handle. This is done by feeding a continuous length of base strip 10 through an extrusion mold 12 that forms a continuous resin cladding 13 surrounding base strip 10 and providing raised shoulders 15 extending along longitudinal side edges of strip 10. Discrete strips 30 are cut from continuous strip 10 and resin cladding 13 is cut and stripped away from end regions 31 of discrete strips 30. Apertures 33 are punched in end regions 31 and discrete strips 30 are assembled into strap handles. Resin cladding 13 can also be cut and stripped away from end regions 31 before discrete strips 30 are cut from continuous strip 10.

Abstract: Cushioned automotive strap handles with spring steel base strips, cushions, and wrapped and sealed covers are made by injection molding resin cladding directly onto steel base strips before assembly with the cushion and cover. The base strips 10 are cut to length with formed end regions 11 which are mounted on a mold part 15 so that a midregion of base strip 10 spans an injection mold cavity 18. Pins 21 within mold cavity 18 locate base strip 10 in a plane spaced from the cavity walls so that the cavity surrounds the midregion of the base strip. The injection molded resin cladding 25 also surrounds the midregion of base strip 10 and provides raised resin shoulders 20 extending along longitudinal side edges of the base strip. The surrounding engagement of cladding 25 secures resin shoulders 20 against transverse movement relative to the base strip.

Abstract: A mount 10 that allows a loop strap 11 to pivot on a horizontal axis between vertical and horizontal positions uses a fixed pivot pin 15 arranged on the horizontal axis for supporting loop strap 11. A sheet metal sleeve 16 wraps loosely around pivot pin 15 and is secured to the ends 17 and 18 of strap 11 so that strap 11 can pivot on pin 15. A cover 20 is arranged over sleeve 16 and strap ends 17 and 18 and has end openings 21 through which pin 15 can pass. A pair of supports 25 and 26 with blind sockets 30 are pressed onto opposite ends 14 of pivot pin 15 and are made to overlap in a central region behind loop strap 11. Overlapping regions 31 and 32 of end supports 25 and 26 are secured to the vehicle so that strap 11 and cover 20 hang downward to conceal the securing mechanism.

Abstract: Molding apparatus 10 or 11 supports a tough, resin ball core 15 in the center of a spherical mold cavity having upper and lower mold parts 12 and 13. Core 15 is about half the diameter of the mold cavity allowing room for foamed resin exterior 16 to form over and around core 15 filling the mold cavity and completing the spherical ball. A pin support 20 formed as a single pin 21 or a pair of identical pins 31 holds core 15 in the center of the mold cavity and is withdrawn after the ball is molded. The pin support is arranged at the mold parting plane and extends through the parts to the mold exterior thus providing full support and accurate location of the core within the mold cavity. A coupling element on pin support 20 is formed as a hook 28 or other engageable element outside the mold and is used for placing the core in the mold and also for supporting the ball for curing after molding.

Abstract: A pull strap handle meeting all the standards of the automotive industry is formed economically with molding operations. The handle is formed with a strip 15 of strong resilient material with high tensile strength that serves as a support element. Support element 15 is enclosed within a molded cover having a firm outer side 17 and a soft inner side 18. Soft side 18 is molded of foamed resin material directly onto support element 15 to form a secure bond. Firm side 17 can be molded in a single operation with soft side 18 or can be molded separately, attached to support element 15, and located in a cavity mold that forms soft side 18. The cover can also be molded to support element 15 within a cavity mold that forms both cover sides 17 and 18 or the cover can be extruded onto support element 15 in a continuous operation.

Abstract: A method of decorating the front surface of a molded resin panel 10 to provide a decorative material 15 in one region 12 and a contrasting decorative coating 18 in another region 14. A resin undercoat 17 and a clear resin top coat 19 are provided for decorative coating 18. The method includes securing decorative material 15 to region 12 of panel 10, masking the decorative material throughout region 12, applying the decorative coating to the unmasked front surface regions of the panel, and unmasking the decorative surface material. A top coat 19 is formed to extend over both decorative coating 18 and decorative material 15 to protect and secure the decorative material with the same top coating that is required for the decorative coating.

Abstract: A caulker 10 dispenses two viscous components contained separately in inner and outer molded resin chambers. The outer chamber 12 holds one of the components 14 around the inner chamber 11 and is generally cylindrical with standard dimensions to fit existing caulking guns and dispensing equipment. The second component 15 is held within collapsible inner chamber 11 aranged inside outer chamber 12 and having accordion pleats that collapse when axially compressed. Inner chamber 11 has a rear end filling opening 17, and a molded resin plunger 13 fitting closely within outer chamber 12 is secured to the rear end of inner chamber 11. The forward regions of both chambers join and form passageways merging at the forward end of caulker 10. Inner chamber 11 is sealed by an openable barrier 22, and a removable closure element 26 seals outer chamber 12.

Abstract: A dispensing system uses a molded resin cartridge 10 and a plunger 11 arranged with an interlock that prevents the plunger from backing out of the rear end of the cartridge. The cartridge wall 12 has an interlock surface 20 just forward of its open rear end 13, and a locking ring 40 has a sleeve 25 extending around the outside of the cartridge wall with a hook 27 that engages interlock surface 20. A radial wall 41 of the locking ring holds the plunger 11 against moving out of the rear end of the cartridge and improves the seal between the plunger and cartridge. The radial wall 41 can be joined to the plunger skirt 15 along a line of weakness 31 that allows sleeve 25 to tear away as the plunger advances to dispense the cartridge contents.

Abstract: A method for molding a product 20 bearing a trim strip 14 first extrudes a supporting base 12 and bonds trim strip 14 to supporting base 12. Then the supporting base 12 is used to position and protect trim strip 14 within a mold 18 where product 20 is formed. Product 20 and supporting base 12 are formed of resin materials that bond together securely as the product is injection molded within mold 18.

Abstract: The apparatus and method for making a resin caulker 10 begins with continuous extrusion of a resin cylinder 15. A multimandrel indexing machine 20 has a receiving station 22 positioned to align an empty mandrel 21 with extruded cylinder 15 so a leading end 18 of extruded cylinder 15 advances onto empty mandrel 21. A cut off device 19 cuts cylinder 15 at a predetermined length to form a resin caulker barrel 11 supported on mandrel 21. Indexing machine 20 then moves cut off barrel 11 to an assembly station 23 and brings another empty mandrel 21 to receiving station 22. An end closure 12 is joined to cut off barrel 11 at assembly station 23; and successive stations 24-29 of the indexing machine finish, print, and dry the assembled caulkers while supported on mandrels 21.

Abstract: A method for forming and selectively decorating a molded resin panel 10 begins with vacuum forming an applique 15 of decorative resin material and fitting applique 15 in an injection molding cavity. Base 11 is then injection molded to applique 15, and a mask 20 is formed to fit over applique 15. A decorative coating 18 is applied over the panel regions not covered by the mask. A resin undercoating 17 is applied under decorative coating 18 which is covered with a top coating 19 of clear resin material.

Abstract: An applicator 15 deposits a solvent-carried adhesive intermittently along a moving strip 10. A sump 26 is arranged below strip 10 to contain a quantity of the solvent 27, and an adhesive wheel 16 rotates with its lower region immersed in the solvent. Adhesive wheel 16 has a continuous periphery on which adhesive is continuously applied, and an applicator wheel 17 rotates against the adhesive wheel and the bottom of the strip above the sump. Applicator wheel 17 a as an intermittent peripheral surface 18 that receives adhesive from the adhesive wheel and applies it in an intermittent pattern to the bottom of the moving strip. The sump, the adhesive wheel, the applicator wheel, and the region of contact between the applicator wheel and the strip are enclosed to retain a substantially saturated solvent vapor atmosphere within the enclosure 25 to inhibit the evaporation of solvent from the adhesive.

Abstract: An automotive trim strip laminate formed of a strip of polyester material bearing a layer of metallic material covered by a thin polyvinyl chloride layer bonded to a supporting substrate of a flexible plasticized polyvinyl chloride material is made so that the laminate can be thermally bonded to a support material along a curved path without any irregularity, which is recognized as caused by compression wrinkling from thermal stress along radially inner regions of the curved path. This is prevented by selecting the polyester strip and the thin polyvinyl chloride layer with physical characteristics and dimensions to provide the metallized polyester strip with sufficient dimensional stability relative to the polyvinyl chloride substrate to prevent any such compression wrinkling, and one preferred way is to make the thin polyvinyl chloride layer substantially unplasticized and formed of a smooth, medium impact material.

Abstract: The inventive method and apparatus make a backout stop for a caulker cartridge having a cylindrical barrel of resin material. The backout stop is formed at the rear end of the barrel as an inwardly oriented hook that has a generally triangular cross-sectional shape. The two exposed sides of the hook are an inclined surface sloping radially inward so a plunger can slide over the backout stop into the rear of the barrel and an abrupt edge extending radially inward to prevent the plunger from backing out of the barrel. The apparatus includes a tool with a socket that fits over the rear end of the barrel and has a resin-forming edge protruding obliquely into the socket to extend along the inclined surface of the hook when the tool is seated on the rear end of the barrel. The barrel and tool are supported on a common axis, are moved into axial engagement, and are rotated relative to each other while pressed together so that the edge plows along the inclined surface and forms the resin material into the hook.

Abstract: An automotive trim strip laminate formed of a thin strip of polyester material bearing a layer of metallic material and bonded to a substrate of a polyvinyl chloride material is made so that the laminate can be thermally bonded to a support material along a curved path without any wrinkling or other irregularity. This is done by longitudinally tensioning the laminate after it has cooled below its annealing temperature following extrusion of the substrate to strain the laminate sufficiently so that it tends to shorten upon reheating to its annealing temperature. The strain is insufficient to cause strain-relief shortening of the laminate at ambient temperatures encountered during storage and transport but is sufficient so that when the strained laminate is held accurately to the curved path and thermally bonded to the support material, its thermal expansion cooperates with strain relief to bring the laminate into smooth and uniform conformity with the curved path.