Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: An air bag cover assembly including an air bag deployment concentrator such as a chute and first and second integrally hinged air bag doors is provided wherein a tear seam is located both inside and outside a channel of the chute. The tear seam interconnects the air bag doors to allow selective air bag deployment through a weakened area formed by the tear seam and portions of the film sheet immediately adjacent the weakened area. The assembly also includes first and second sets of hinges for hingedly connecting the first and second air bag doors, respectively, to a front panel both inside and outside the channel to facilitate pivotal movement of the air bag doors away from the air bag to allow deployment of the air bag through the channel, through the weakened area and through the portions of the film sheet during impact of the vehicle.

Abstract: Energy-absorbing bolsters for an automotive instrument panel assembly are provided wherein each of the bolsters includes a network of thermoplastic cells having a plurality of interconnected sides for absorbing energy of an impact with a front panel by a passenger of the vehicle in an energy absorption area of the front panel. Each bolster includes a thermoplastic cover section including the front panel having a front outer surface and a rear inner surface. A thermoplastic rib structure lays immediately behind the rear inner surface of the front panel in the energy absorption area. A thermoplastic backing section includes a back panel having a rear outer surface and an inner surface and is secured to the cover section in containing relationship to the rib structure to form a hollow compartment for the rib structure in the energy absorption area.

Abstract: Lightweight, thermoplastic, vehicle headliners each having at least one integrally-formed, energy-absorbing, head-impact mechanism and injection molding methods for making same are provided. Each headliner includes a stiff, self-supporting, thermoplastic sheet adapted to be mounted adjacent a roof of the vehicle so as to underlie the roof and shield the roof from view. The sheet has an upper surface and a lower surface. Each energy-absorbing, head-impact mechanism absorbs energy of an impact with its associated headliner by a passenger of the vehicle. In one embodiment, the at least one head-impact mechanism includes a plurality of spaced-apart, energy-absorbing, thermoplastic structures, such as ribs, which are connected to and extend upwardly from the upper surface of its thermoplastic sheet.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A vehicle body front end preassembly and method of making a vehicle front end assembly is disclosed. According to the method of the present invention, the integrated front end module (10) is injection molded to include integrally molded fastener receptacle (32) and integrally molded reinforcement ribs (28) that are injection molded from a fiber reinforced thermoplastic polymer. A partially assembly vehicle body (12) is provided that has partially unattached body panels that are secured to the frame (14). Unattached body panels are secured to the integrated front end module (10). The preassembly is then immersed in an electro-coat bath, painted and then baked in a paint oven.

Abstract: An occupant protection system which deploys a deployable air bag from a concealed inner location in a vehicle instrument panel having an opening. An air bag portion covers the opening sufficiently to conceal the air bag in a concealed location. Upon deployment, the air bag portion remains as a portion of the air bag. This allows the air bag to inflate and fully deploy uninhibited, and eliminates the potential for an air bag cover or pieces thereof to be propelled toward, and injuriously impact, the occupant.