Abstract: A drawer pedestal including a structural support for reinforcing working surfaces of the pedestal. The drawer pedestal includes a shell and a substructure that define a cavity. The shell includes a panel that forms the top surface of the pedestal. A first structure, preferably defining a compartment, projects into the cavity. The support includes first and second side panels connected to one another by a top support panel. In a preferred embodiment, the support is frictionally fit between the first structure and the top panel of the shell to reinforce that top panel. In a more preferred embodiment, the support is constructed from expanded polystyrene foam. The support optionally includes openings that accept guide tabs on the substructure or shell of the drawer pedestal.

Abstract: A soft-touch drawer pull including a substantially rigid substrate and a rubber-like plastic attached to the outer surface of the substrate. The substrate preferably includes teeth or catches on an inner surface that interact with corresponding recesses or holes on a drawer unit or other article to allow the drawer pull to be easily secured to the unit or article. Preferably, the drawer pull further includes catches that interact with snaps on a drawer to further secure the drawer pull to the drawer.

Abstract: A drawer pedestal including a shell and a substructure that snap together. The substructure includes multiple locking tabs around a peripheral flange that interlock with slots defined by a peripheral rim of the shell so that the two pieces can be easily snapped together. At least one of the shell and the substructure include guide tabs to guide the two parts into the appropriate position for interlocking. The invention also provides a method for assembling the drawer pedestal including: positioning the substructure adjacent to the shell; aligning first and second locking structures on the substructure and shell; and moving at least one of the shell and the substructure toward one another until the first and second locking structure engages one another.

Abstract: A process for injection molding a composite of rigid thermoplastic and soft thermoplastic, the soft thermoplastic including a cavity established with pressurized assist gas or an assist liquid. The process includes the steps of: injecting a hard molten thermoplastic into a first mold chamber; injecting a soft molten thermoplastic into a second mold chamber; establishing communication between the first chamber and the second chamber so that the rigid thermoplastic and soft thermoplastic integrally bond; and injecting an assist fluid into the soft thermoplastic to form a cavity. In a preferred embodiment, the formed composite is an automotive cowl where the rigid thermoplastic forms the rigid body portion of the cowl and the integrally bonded soft thermoplastic forms a compressible bulb seal.

Abstract: A process for injection molding a composite of rigid thermoplastic and soft thermoplastic, the soft thermoplastic including a cavity established with pressurized assist gas or an assist liquid. The process includes the steps of: injecting a hard molten thermoplastic into a first mold chamber; injecting a soft molten thermoplastic into a second mold chamber; establishing communication between the first chamber and the second chamber so that the rigid thermoplastic and soft thermoplastic integrally bond; and injecting an assist fluid into the soft thermoplastic to form a cavity. In a preferred embodiment, the formed composite is an automotive cowl where the rigid thermoplastic forms the rigid body portion of the cowl and the integrally bonded soft thermoplastic forms a compressible bulb seal.

Abstract: A process for injection molding a composite of rigid thermoplastic and soft thermoplastic, the soft thermoplastic including a cavity established with pressurized assist gas or an assist liquid. The process includes the steps of: injecting a hard molten thermoplastic into a first mold chamber; injecting a soft molten thermoplastic into a second mold chamber; establishing communication between the first chamber and the second chamber so that the rigid thermoplastic and soft thermoplastic integrally bond; and injecting an assist fluid into the soft thermoplastic to form a cavity. In a preferred embodiment, the formed composite is an automotive cowl where the rigid thermoplastic forms the rigid body portion of the cowl and the integrally bonded soft thermoplastic forms a compressible bulb seal.

Abstract: A dashmat for use in a vehicle passenger compartment comprising a firewall separating the passenger compartment from an engine compartment and a floorboard extending rearwardly from the firewall. The dashmat comprises a decoupling layer shaped to span the width of the vehicle passenger compartment. The decoupling layer has a lower surface adapted to abut the firewall and floorboard, and an upper surface adapted to face an interior of the passenger compartment. A header is formed in a front portion of the decoupling layer and is adapted to connect to a supply duct from a vehicle HVAC system. An air distribution channel is formed in the decoupling layer and extends rearwardly from the header through a substantial portion of the decoupling layer for distribution of conditioned air from the header throughout at least a front portion of the vehicle passenger compartment.

Abstract: A vacuum wrapping process and apparatus for adhering a flexible material to a rigid substrate. The temperature of the flexible material is monitored, processed, and controlled by a control unit. The material is supported over the substrate in a mold. Spring-loaded rotatable bars are supported within the mold and compress the marginal portion of the material against the mold. A vacuum draws the material toward the substrate, and the bars control the release of the material at a desired rate. The vacuum drawn on the material is monitored, processed and controlled by the control unit. The amount of vacuum applied to the material is inversely related to the temperature of the material. The control unit alters parameters of the vacuum molding process, such as the material temperature and the vacuum to reduce tearing, stretching, and/or wrinkling of the material.

Abstract: A waste container has an axle assembly comprising an axle with opposing axle end caps adapted to mount the wheels of the waste container. The axle comprises a metal rod encapsulated in plastic. An annular axle groove is formed near the ends of the axle in the encapsulating plastic. The metal rod provides the necessary strength for the axle and the encapsulating plastic protects the rod from corrosion while permitting the formation of the annular axle grooves used for mounting the axle to the wheel. The axle can easily be injection molded, reducing the cost and manufacturing time of prior axles while still providing corrosion protection.

Abstract: A waste container having a wheel assembly comprising an axle assembly on which are slidably mounted a pair of wheels. The axle assembly comprises a pultruded shaft with opposing end caps. The end caps have an indentation for receiving a retainer to retain the wheels on the shaft.

Abstract: The invention relates to a waste container of the type typically used in residential waste collection systems. The waste container includes a container body having opposing side walls that extend upwardly from a bottom wall to form a waste compartment with an open top for access thereto. The bottom wall of the container body is reinforced by a series of corrugations to increase the rigidity of the bottom wall to prevent sagging, which can result in premature wear and failure. The corrugations also increase the heat transfer rate of the bottom wall, which improves the cooling characteristics of the waste container during molding. The corrugations further provide airflow channels for the injection of air between the container body and a mold during the molding process to improve the ease of removing the waste container body from the mold and to prevent stretching in the bottom of the container during the molding process.

Abstract: Molding of relatively large articles such as automobile body parts by gas-assisted injection molding with sequential gating of injected thermoplastic resin into the mold cavity. Elongated ribs in the parts form gas channels and strengthening ribs for the parts. Structural parts are made by adhesively joining two such parts made by gas-assisted injection molding through a combination of hollow ribs and joining flanges at sides of the parts.

Abstract: Molding of relatively large articles such as automobile body parts by gas-assisted injection molding with sequential gating of injected thermoplastic resin into the mold cavity. Elongated ribs in the parts form gas channels and strengthening ribs for the parts. Structural parts are made by adhesively joining two such parts made by gas-assisted injection molding through a combination of hollow ribs and joining flanges at sides of the parts.

Abstract: A dash mat for blocking the transfer of sound from a vehicle engine compartment, through a firewall, and into a passenger compartment. The dash mat being mounted to the firewall and comprising a planar sheet in which is formed a channel for receiving a vehicle accessory, such as a wiring harness, and a pair of resilient fingers positioned on opposite sides of and overlying the channel to hold the vehicle accessory within the channel.