Abstract: An air bag cover door assembly utilizes a releasable fastener along each side of the air bag cover door to provide a predetermined opening characteristic for the cover door. The fasteners can be hook and loop tape, mechanical interlocks, adhesive strips, etc., with one half of each fastener secured to the inside surface of the cover door and the other half secured to a substructure, such as a dashboard pad retainer, in mating engagement with the first half. The fasteners are located along the sides of the cover door proximate the hinging axis of the cover door so that expansion of the air bag causes the cover door to initially hinge along a line extending between the engaged fasteners and then causes the fasteners to separate, allowing the cover door to swing open fully about its hinging axis.

Abstract: An insert and method of molding the insert for use with an instrument panel or the like of a vehicle and in which the insert serves as a structural part of a cover for an air bag assembly and is provided with a door which opens upon being impacted by the inflating air bag and in which the door is formed of a flexible plastic material that is bonded in certain areas to the insert and has its plastic material interlocked with the plastic material of the insert in areas which serve as a hinge for the door.

Abstract: An air bag restraint system is housed within an interior trim product with a hidden door that is opened when an air bag is inflated for deployment into the passenger car or a vehicle. The door is formed in a reinforced segment of a layer of low density rigid foam material that forms the load bearing support for the interior trim product and a backing for an outer skin or decorative surface that forms the outer cover of the interior trim product. The hidden door is formed by cast in place segments in the reinforced segment of the layer of low density rigid foam material a door hinge segment and a weakened tear seam segment which separates when the air bag impacts thereagainst to tear the outer skin for forming an opening therethrough for deployment of the air bag into the passenger compartment of a vehicle.

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: A closure for an air bag assembly includes a flexible outer skin and a layer of foam material covering a retainer member having an air bag deployment opening therein closed by a moveable door that is overlapped with the retainer member to support the door against movement inwardly of the retainer member while providing free hinging movement thereof with respect to the retainer member for stressing and separating the layer of foam and the outer skin for forming a deployment path therethrough for the air bag.

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: Apparatus for heating and cooling a mold onto which thermoplastic material is cast and fused to form a finished article includes a plenum having an inlet and an outlet for connection to a fluid heating and cooling system and a mold box having a plurality of cavities for selectively receiving interchangeable tube bundles that are selectively positioned in a movably sealed relationship within the mold box and wherein each tube bundle has a mold and a tube array that are maintained in a fixed relationship during interchange thereof into and out of said mold box so as to maintain individually heat balanced molds.

Abstract: A collapsible arm rest for a passenger compartment of a motor vehicle comprises a flexible skin or covering, a layer of foam material underlying the flexible skin to provide a cushion and soft feel for the collapsible arm rest, a back plate for securing the collapsible arm rest to a generally vertical panel of a motor vehicle, and an insert embedded in the foam layer for strengthening the arm rest. The insert comprises a hollow bellows shaped thin walled shell that is attached to the back plate so that the shell collapses in the lateral direction when the arm rest is subjected to a side load of the type experienced in a side impact automobile collision. The shell defines an empty chamber that communicates with ambient air in the exterior environment of the arm rest via a small open vent and a large vent that is covered by a rupturable membrane that ruptures when the shell collapses in the lateral direction to avoid pneumatic delay in the lateral collapse of the shell.

Abstract: A method and apparatus is disclosed for forming a cover for an air bag deployment opening, the cover having a tear seam defined by a reduction in thickness of the cover. The cover can be formed as an unitary part of an outer skin layer for an automobile interior trim structure. The apparatus includes a thin shell having an inner surface upon which a thermoplastic material is cast to form the outer skin. A multiplicity of pins are disposed on and extend away from a backside thereof to transfer heat to the inner surface. The density of the pins is reduced on the portion of the backside of the shell proximate the portion of the inner surface upon which the tear seam of the outer skin is to be formed. The shell can be heated or cooled by using a plurality of nozzles to impinge heated or cooled air onto predetermined locations of the backside. A cover and tear seam construction is also disclosed.

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 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: 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 steering wheel (12) incorporates an air bag unit (22). The air bag unit has a cover door (30) that has a bladder (38) with an air chamber (39) in communication with a pressure sensor (40). The pressure sensor is incorporated in an electrical circuit (42) that is actuated when the pressure sensor senses pressure within the bladder to be above a predetermined value. The electrical circuit is connected to a horn (44) such that when the bladder is pressed, the horn is actuated.

Abstract: A door trim panel includes a cover assembly for concealing an air bag restraint system that has an air bag, a housing for the air bag and a gas generator located in the housing for supplying gas to the air bag in response to vehicle impact. The cover assembly includes a frame defining an air bag opening and a flexible covering attached to the frame in a taut manner. The flexible covering which is juxtaposed the air bag has a single tear seam that is ruptured when the flexible covering is impacted by the inflating air bag and forms an elliptic opening for deployment of the air bag into the passenger compartment.

Abstract: A method is disclosed for forming a reinforced plastic skin for an automobile interior trim structure. The method includes the steps of supplying a plastic material onto a mold surface, heating the plastic material to fuse it into a unitary layer, embedding a reinforcing material into the layer, and cooling the plastic and reinforcing materials. The method can be used to reinforce an air bag door cover by incorporating a tear seam into the plastic layer and embedding the reinforcing material into the layer such that it surrounds the tear seam. The reinforcing material aids in rupturing of the cover along the designated tear seam during deployment of the air bag. Also disclosed is an air bag door cover formed in accordance with the disclosed method.

Abstract: Spray apparatus for mixing, atomizing and spraying foam forming components has a hollow wand of extensive length that is adapted to be connected at one end to a conventional mixhead and has mounted therein a static mixing element that extends the length of the wand. A nozzle having a singular central orifice through its tip is mounted on the distal end of the wand and houses a floating core. The core has a convex end facing the orifice and is contactible thereabout with an interior side of the nozzle tip. The mixing element has a spiral shape that operates to incite turbulence and thereby enhance mixing of the foam forming components passing through the wand from the mixhead. The core has a peripheral surface that converges in the direction of the orifice and angled channels in this surface separate the mixed components into streams directed toward the orifice and together with the orifice atomize the mixed components and cause the discharge thereof in a uniform atomized cone-shaped spray pattern.

Abstract: A laminated instrument panel has a door cover for concealing a supplemental inflatable restraint (SIR) system in a vehicle passenger compartment that includes a skin flap that is an integral part of the skin of the instrument panel. The skin flap is cast out of position and collapsed into the correct position when an elastomeric foam layer is foamed in place beneath the cast skin. This forms slanted grooves in the skin at the juncture of the flap and the adjacent skin of the instrument panel that have little or no gap at the surface of the skin. The skin flap can be shaped to provide a flush door or a raised door with an overlapping front edge.

Abstract: An air bag cover door for a steering wheel mounted air bag module includes an inner cover, an outer cover, a horn actuator attached to the inside surface of the outer cover, and one or more protrusions extending between the inner and outer covers about the horn actuator. The protrusions prevent the inner cover from compressing the horn actuator under the pressure exerted by the stored material of the air bag. The outer cover, including its inside surface, is deformable upon hand pressure being exerted thereon and the horn actuator is responsive to such deformation to activate the vehicle horn. The horn actuator can be a transducer, such as a variable resistor, adhered to the inside surface. The inner cover is permanently secured to the base of the air bag module by, for example, rivets, while the outer cover section is removably secured to the base by, for example, screws.