Abstract: A pressure relief valve such as is used to relieve over-pressure in the passenger compartment of an automotive vehicle has valve flaps which are retained in connection with a housing by molded-in-place retainer strips. The valve is manufactured by an injection molding tool having a pair of mold halves defining a first mold cavity for forming the housing and a second mold cavity for forming the flaps. After the housing and flaps have set, the mold is opened, with the housing remaining in contact with one mold half and the flaps remaining in contact with the other mold half. One mold half is then moved relative to the other to place the housing and the flaps in alignment with one another, and the mold halves are closed again to place the flaps inside the housing and define a third mold cavity extending along the lines of desired attachment between the flaps and the valve seats.

Abstract: A method of making a composite comprises applying controlled heating to a bonding surface of a preformed substantially rigid thermoplastic substrate to cause the bonding surface to flow, without causing substantial heat soaking, melting, or other damage to a residue portion of the substrate, or a second component known as a bonding layer. The method further comprises causing pressurized contact at an interface between the bonding surface and the bonding layer, while the bonding surface is in a flow state. The invention further contemplates an apparatus for making a composite, comprising a heater capable of applying controlled heating to the bonding surface, and a bonding device in communication with the heater for creating pressurized contact at the interface between the bonding surface and the bonding layer, following controlled heating.

Abstract: A method for making a soft trim composite, and a resulting improved soft trim composite, used for example as a motor vehicle interior trim component or a seat covering component, comprises laminating a surface covering onto an expanded cellular layer, where a cellular layer is provided, to form a bilaminate, and placing a heat barrier insert, comprising nonwoven fibers coated on one side with thermoplastic resin in a mold between the bilaminate and a substrate created in a molding step. The heat barrier insert dissipates heat from substrate molding, permitting a substantially uniform and complete bonded relation to be achieved between substrate and insert, as well as between insert and bilaminate, virtually simultaneously with creation of the substrate, and without causing substantial damage to the bilaminate. An improved soft trim composite made by the method described, is also provided.