Abstract: A trim panel having an integral handle is made using a subassembly comprising a structural substrate that has a handle hole and a handle frame that spans the handle hole. The subassembly is mounted on a pneumatic buck and a sheet of pliable and stretchable expanded vinyl plastic is then draped over the subassembly to form a decorative cover for the trim panel. The plastic sheet is then vacuum drawn against the top of the subassembly and partially around the handle frame. Draped portions of the plastic sheet between the handle frame and the handle hole, are then cut and trimmed, to complete the wrapping of the handle frame and the edge of the handle hole. The cut ends of the draped portions wrapped around the handle frame are tucked in a longitudinal slot in the underside of the handle frame.

Abstract: A process for the production of a rigid multi-layer composite articles (20) prepared from reacting inter alia a sheet of an open cell foam material (22) impregnated with a binder resin, such as isocyanate resin, to fill the cells of the foam material (22) and a polymerization catalyst to cause the reaction of isocyanate and form isocyanurate linkages, urethane linkages, urea linkages, trimer linkages, biuret linkages, and/or allophante linkages to render the composite article (20) rigid, and having a layer of reinforcing fibers, such as glass fibers, completely (24) or partially (25) impregnated by the binder resin affixed to a surface of the foam material (22) by the binder resin. Fasteners (27) formed of a thermoplastic material are provided having an appropriate adhesion surface. The adhesion surface of each of the fasteners (27) is melted by any of the well known techniques such as spin welding, etc.

Abstract: An arm rest (18, 20, 22) is mounted for vertical adjustment relative to the door panel (14) or center console (16). The arm rest is operably connected to an air spring bladder (32, 46, 54) or an adjustable mechanical mechanism (72). The bladder is controlled by a pump (40) and switch (41). The mechanism (72) is controlled by an electric motor (70).

Abstract: An automotive instrument panel includes a molded plastic retainer formed with an integral airbag deployment door surrounded by a channel defining a tear seam enabling the door to separate and hinge outwardly upon deployment of the airbag. A foam-backed cover of flexible plastic material is applied over the outer surface of the panel and is severed along the length of the channel to eliminate any influence that the cover may have on resisting the opening of the door. The severed cover portion can either be removed to expose the door or else be left in tact and bonded to the door.

Abstract: A process for the production of a rigid multi-layer composite articles (20) prepared from reacting inter alia a sheet of an open cell foam material (22) impregnated with a binder resin, such as isocyanate resin, to fill the cells of the foam material (22) and a polymerization catalyst to cause the reaction of isocyanate and form isocyanurate linkages, urethane linkages, urea linkages, trimer linkages, biuret linkages, and/or allophante linkages to render the composite article (20) rigid, and having a layer of reinforcing fibers, such as glass fibers, completely (24) or partially (25) impregnated by the binder resin affixed to a surface of the foam material (22) by the binder resin. Fasteners (27) formed of a thermoplastic material are provided having an appropriate adhesion surface. The adhesion surface of each of the fasteners (27) is melted by any of the well known techniques such as spin welding, etc.

Abstract: An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.

Abstract: A heat insulating panel (20) for a mold tool (14) includes a surface for being mounted onto a section of the mold tool. The panel has an exposed upper surface (29) and a thickness great enough to provide heat insulation sufficient to maintain the temperature at its exposed upper surface lower than the melting temperature of a powder plastic resin (13) that is melted and cured onto the mold tool. Any powder plastic resin on the upper surface remains in powder form during molding such that the powder may be returned to a powder box (12) and be reused. The heat insulating panel (20) has a periphery (21) that covers the entire periphery of the mold tool.

Abstract: An underwater thermoplastic pelletizer has an extruding die, and a cutter for cutting a thermoplastic polymer extruded from the die into pellets as the molten polymer is solidified under water that is circulated to cool the extruded polymer and convey the pellets away for collection. The extruding die includes a die plate that is mounted in the face of the die concentric with and opposite the cutter and has a plurality of groups of extruding die holes that are connected in the die to a central main feed passage by separate radially extending distribution feed passages. The die holes in the groups are arranged in circular patterns of uniform radius about a center line intersecting with a circle concentric with the cutter path and the groups are equally angularly spaced about the cutter center line.

Abstract: An instrument trim panel (12) includes a shell (14) made from a flexible plastic material. A textured section (18) is circumscribed by a simulated seam (20). A closed cell plastic block (28) is press fitted behind the textured section. An air pocket (26) is interposed between the block and textured section. A rigid substrate (22) is molded and cured behind the shell (14) and block (28). The air pocket allows the textured section to be deformed to simulate the appearance and feel of a leather applique.

Abstract: A steering wheel (12) incorporates an air bag unit (22). The air bag unit has a cover door (30) with a transducer (38) molded in a deformable front wall (35) of the cover door. The transducer can be a force sensitive resistor (38) which is operably connected to an electrical circuit (42) that actuates a horn (44) when the circuit senses a change in the resistance of force sensitive resistor (38). The force sensitive resistor (38) produces a suitable change in resistance when hand pressure is exerted on the front wall (35).

Abstract: The molding apparatus includes a press (10) with a top mold (12) and a bottom mold (14). The top mold (12) has a die (32) with a contoured die surface (34) and gas passages (36). The bottom mold (14) has a die 44 with a contoured die surface (46). The die (44) is made from either a solid piece of material with gas passages or from a porous material. During operation of the molding apparatus, a workpiece (26) is placed in a mold cavity between the top mold and the bottom mold. The mold cavity (24) is closed to shape the workpiece. The workpiece is heated by hot gas supplied by a gas supply and recirculation system (52) when the diverter valves (68 and 70) are opened and gas flows from gas circulation fan 56 to the gas heater chamber (54) to the bottom mold (14), through the die 44, through the workpiece (26), through the die 32 and back to the inlet side of the gas circulation fan (56).

Abstract: A nozzle assembly (16), for spraying a liquid such as a urethane prepolymer on a substrate, has a liquid spray nozzle (28) with a center line (56). Air nozzles (30), with center lines (62) that are substantially parallel to the center line (56) of the liquid spray nozzle (28), are provided in the nozzle assembly (16) around the liquid spray nozzle. Air passing from the air nozzles (30) surrounds and encloses the liquid spray and decreases the size of the liquid spray fan pattern (58 or 70). The air spray nozzles (30) can be positioned in the nozzle assembly (16) to change the shape of the liquid spray fan pattern (58 or 70) as well as the size. Mixing of air and liquid is minimized by spraying air and liquid in parallel paths.

Abstract: An interior trim product and supplemental inflatable restraint assembly includes a canister for generating gas to inflate an air bag for deployment into the passenger compartment of a motor vehicle. Access to such assemblies is closed by a door that is held down by a cable release mechanism that will separate from the door as the door is opened during supplemental inflatable restrain deployment.

Abstract: The mold (10) for forming an article includes a first mold member (16) with a first mold surface (24) and a second mold member (18) with a second mold surface (26). When the mold (10) is closed, the first and second mold surfaces (24) and (26) form a mold cavity (28). Lances (58) are forced into the mold cavity (28) by linear actuators (60) to pierce an article (12) and then withdrawn from the mold chamber. Each Lance (58) allows gas under pressure to escape from the article (12) through the clearance between the lance and the bore (56) in which the lance is mounted. Relieving gas pressure in the article (12) allows the mold (10) to be opened without distortion of the article and shortens mold cycle time.

Abstract: The soft interior trim panel (52) includes a substrate (54), a foam layer (56) and a flexible skin (58). An electrical switch (60) is supported by the trim panel (52) adjacent to the flexible skin (58). A contoured area (62) and indicia (64) indicate the location of a switch (60) under the flexible skin (58). A clear coat (65) is applied to protect the flexible skin (58) and the indicia (64). The switch (60) is closed by applying pressure to the flexible skin (58) on the contoured area (62). The contoured area (62) can be a depression or indentation as well as a raised area. The indicia (64) can be provided using luminescent ink.

Abstract: The molding apparatus includes a press (10) with a top mold (12) and a bottom mold (14). The top mold (12) has a die (32) with a contoured die surface (34) and gas passages (36). The bottom mold (14) has a die (44) with a contoured die surface (46). The die (44) is made from either a solid piece of material with gas passages or from a porous material. During operation, a workpiece (26) is placed in a mold cavity (24). The mold cavity (24) is closed to shape the workpiece. The workpiece is heated by hot gas supplied by a gas supply and recirculation system (52) when the diverter valves (68 and 70) are opened and gas flows from gas circulation fan (56) to the gas heater chamber (54) to the bottom mold (14), through the die (44), through the workpiece (26), through the die (32) and back to the inlet side of the gas circulation fan (56). When the workpiece (26) has been heated to the desired temperature for the required time, the diverter valves (68 and 70) are closed.

Abstract: An air bag cover assembly includes a support that has an opening for deployment of an air bag and a door that is connected to the support at one end for movement between a closed position closing the opening in the support and an open position for deployment of the air bag. The outer surface of the support and the door are bonded to an elastomeric foam cushion formed in an underlying relationship to a polymeric skin that forms a covering of the cover assembly. When the air bag is deployed, it impacts an impingement member that cooperates with a reaction member so that edge tabs on one of the members rotate laterally in the elastomeric foam cushion and assist in tearing the elastomeric foam cushion and polymeric skin apart to release the air bag door.

Abstract: A venting device for a rotocast shell mold body having a neck and a flanged neck plate thereon. The venting device is a tube formed of black iron pipe of a predetermined diameter and length and mounted in an opening formed in one of the neck or a cover mounted on the neck plate, and extended for approximately half its length into the interior of the mold. When used with the neck of the mold, the tube is welded in place, and when used with a mold cover, the tube is threadedly mounted therein.

Abstract: A cover assembly for an airbag restraint system has a smooth, grained, plastic cover and a load bearing insert for covering a housing for an airbag and a gas generator which includes an inflatant for the airbag for deploying the airbag through the smooth, grained plastic outer cover member without rupturing the cover member at weakened sections therein and wherein a carriage is formed in an insert opening having a cutter thereon between the cover and the air bag; the cutter has cutting edges thereon directly contacting the cover assembly for perforating the cover during inflation of the airbag so as to form a self-piercing cover assembly which will be cut to form an opening through the cover assembly through which the airbag is deployed; the self-piercing occurring as the airbag is inflated and solely in response to such inflation prior to deployment of the airbag into the passenger compartment.