Abstract: An airbag cover assembly for the passenger side of an automobile. The assembly includes an exterior skin, a pair of underlying sub-assemblies, each including a U-shaped galvanized steel strip, a short nylon scrim and a long glass mat sandwiched therebetween and extending therefrom such that a narrow space exists between adjacent edges of the glass mats. A weakening notch is formed across the inside surface of the exterior skin along the center line of the narrow space. A low density polyurethane foam is injected into a foaming tool cavity bearing the skin and pair of sub-assemblies. When cured, the foam covers the nylon scrims and glass mats and becomes immersed throughout the interstices of each, serving as the body of the final assembly. The glass mats prevent fragmentation of the low density foam upon deployment of the airbag.

Abstract: A cover for an armrest access opening to the mounting or attachment apparatus for the armrest, wherein the cover is formed of the same vinyl skin which covers the armrest and is integral therewith. The cover is a vinyl skin flap connected by a living hinge to an edge of the vinyl skin covering the armrest adjacent the access opening. A small opening is formed in the top surface of the mounting apparatus, and a plug is formed on the inner surface of the flap, adapted to fit into the small opening and support the flap once the flap is closed over the access opening.

Abstract: A method for repairing voids in a finished urethane foam product having a typical backing insert or retainer wall, the method including the steps of forming a hole through the retainer wall adjacent the void; inserting a small elastomeric sheath through the hole into the void; injecting a urethane or silicone elastomer into the sheath to fill same to conform to the void; and sealing off the hole with a suitable plug which may be sanded flush with the retainer wall outer surface.

Abstract: An improved interior automotive door panel assembly including integrally molded fasteners adapted to being connected to openings formed in the outer metal door structure. In an alternate embodiment the interior door panel assembly including the integrally molded fasteners has a bezel detachably mounted on the fasteners thereof by the interior door panel assembly supplier. The bezel is adapted to being automatically adhesively secured to the metal door assembly along the vehicle assembly line by the vehicle manufacturer. The interior door panel and fasteners may be subsequently removed from the bezel in the field.

Abstract: A vehicle dash board comprises a support mounting a storage compartment for an inflatable air bag, a resilient covering for the dash board, and an opening in the support for enabling deployment of the air bag upon inflation outwardly of the dash board. A decorative panel carried by the support and concealing the storage compartment comprises a backing plate having a U-shaped cut line framing the opening and defining a door. A rod is carried by the support and engages the backing plate along a line connecting the ends of the cut line at the top of the U to provide a hinge line for the door. A resilient layer of material overlies the backing plate and comprises an outer flexible skin layer and an intermediate resilient foam layer bonded to the support and skin. The skin layer has an end flap on its free side opposite the hinge line which is stitched to the adjacent dash board covering so as to define a tamper proof door seam which cannot be pried open either by intention or inadvertance.

Abstract: An automotive side impact protection apparatus including a face plate formed on the inner lower portion of the door, and reinforcement structure operatively connected to the underbody and interfacing with the face plate. In one embodiment, the reinforcement structure is a cantilevered brace extending diagonally upwardly from the underbody intermediate the seat and the face plate. In another embodiment, the reinforcement structure is a reinforcement member extending laterally through the seat just inside the bottom surface thereof, with an enlarged portion formed on the outboard portion of the member adjacent the face plate, and reinforcement trusses between the member and the underbody.

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.

Abstract: A delivery system for dispersing either hot air or water uniformly to the outer surface of a shell mold used for forming a thin molded shell, for the respective fusion and cooling phases thereof. The delivery system includes a plurality of distributors, each having a central water inlet surrounded by an axially adjustable outer shell, with the latter having a frusto-conically shaped upper end which cooperates with the upper edge of the central water inlet to selectively close off or vary the annular opening therebetween for controlling the flow of air at a predetermined temperature form the space intermediate the central water inlet and the surrounding outer shell.

Abstract: A vehicle bumper assembly has a fascia covering a layer of compressible energy absorbing plastic material with a cavity formed therein; the cavity contains an inflatable bladder connected at a header plate to a fill port and an exhaust port. The exhaust port is connected to a relief valve and an orifice for controlling exhaust of gas from the inflatable bladder to control the point at which deflation of the air bag starts and the rate of deflation; the fill port is connected to a gas source operative in response to vehicle impact to generate a gas charge for inflating the bladder to fill the cavity and provide energy absorbing capacity in addition to that provided by the compressible energy absorbing plastic material.

Abstract: Apparatus for making composite doors includes means to locate a plastisol skin cover having an integral sail pocket formed therein within a mold cavity having a lid thereon moveable between opened and closed positions. The lid includes a retractable tool for positioning a hollow substrate extension in the sail pocket to both seal against foam leakage into the hollow substrate extension and to center the substrate extension within the pocket for defining a foam reaction space between the pocket and the substrate extension. A method for making integral 360.degree. sails on a composite door includes the steps of casting a fused plastisol skin having an integral 360.degree.

Abstract: A method for forming a return flange on the belt trim portion of a vehicle door panel which includes the steps of locating the door panel on a holding fixture to place the belt trim portion for sequential clamping, backing, spot heating and folding to form the return flange thereon; apparatus for practicing the method which includes a door fixture means with movable backing member to back a belt trim portion when the panel is clamped in place; and a heater mechanism and a flange former mechanism on the machine are sequentially advanced with respect to the clamped door panel to soften a thermoformable segment of the panel which is folded about the back-up plate.

Abstract: An interior trim product has an opening therein formed to overlie an air bag restraint assembly including a canister for generating gas for inflating an air bag for deployment into the passenger compartment of a motor vehicle. The opening is closed by a door having a vinyl outer covering matching the aesthetic appearance of the outer surface of the interior trim product and including a soft foam backing formed by reaction injection molding foam between the vinyl skin and a first substrate having construction holes therein; a second substrate is connected to the first substrate to cover the holes and to reinforce the door to prevent foam and vinyl damage during air bag deployment and wherein the second substrate is adapted to define a hinged connection between the door and a releasable connection at the opposite end of the door for holding it in place within the opening against separation therefrom until an air bag is inflated and deployed into the passenger compartment.

Abstract: A bumper assembly having a fascia and a support member including an integral core made of a fiber reinforced composite resin adapted to be connected to a vehicle frame. The integral core has a back plate portion adapted to extend vertically of the front end of a vehicle and a plurality of reinforcing boxes formed with the back plate and extending forwardly and transversely. One of the reinforcing boxes is located at the top of the back plate and another is located at the bottom of the back plate. A cavity between the back plate and the fascia is filled with an energy absorbent material.

Abstract: A shell mold support apparatus for rotationally casting thermoplastic polymer particles onto a heated casting surface to form a thin polymer shell conforming to the shape of a heated casting surface includes a base framework that supports a bottom shell mold; a cover carrier is supported on the base framework so as to either open or close a cover or top shell mold with respect to the bottom shell mold; and a hinged support couples the cover carrier to the base framework for movement against an opening stop.

Abstract: A method for molding a thin walled plastic shell utilizes the following apparatus. An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).

Abstract: A hot knife assembly for cutting excess organic polymeric material from a thermal forming mold includes a blade-like knife in the form of a thin flat plate having an inner edge connected to a heater and an outer edge with a cutting surface thereon. The thin flat plate has two flat surfaces substantially encapsulated by a refractory wedge. The refractory wedge in formed silicone material and extends coextensive and adjacent the blade-like knife for preventing stringing or re-welding of the cut material.

Abstract: A pour head seal assembly for a mold including a mold cavity part and a lid, with a film layer against the inner surface of the lid and a preformed shell against the inner surface of the mold cavity part. The pour head seal assembly may be operatively mounted on either the lid or the mold cavity part, including a nozzle mounted through an opening formed in the selected element, with either the film layer or the preformed shell having an opening formed therein for mounting around the nozzle. A clamp plate collar is mounted on the inner end of the nozzle, adapted to clamp either the film layer or the preformed shell against an O-ring seal mounted on the adjacent inner lid or mold cavity surface to eliminate foam leakage around the nozzle.

Abstract: An assembly (10) for molding a two-tone, thin-walled plastic shell (12) for parts such as automobile door panels, control and instrument panels and the like includes a charge box (24) for supplying dry thermoplastic material to separate casting surfaces (30, 32) on a heated mold (22) selectively connected to the charge box (24) during the casting process. A pressurized inflatable seal gasket (60) is connected to the charge box (24) for sealing a division surface (36) on the heated mold (22) which surface (36) separates the casting surfaces (30, 32) of the mold (22). The seal gasket (60) is attached to the charge box (24) on a divider wall (42) via a sliding member (80) which positions the seal gasket (60) longitudinally along the divider wall (42). The sliding member (80) is secured to the divider wall (42) via threaded pins (86). The gasket seal (60) may be removed and reinserted in the slider member (80) providing automatic adjustment thereof.

Abstract: A cover assembly for an airbag restraint has a smooth cover and a load bearing insert for concealing an airbag restraint system having a housing, an airbag and a gas generator which includes an inflatant for inflating the airbag for deploying the airbag through the smooth outer cover member. The outer cover member has weakened sections on the inboard surface and filler material is disposed against the cover member to prevent inward collapse of the outer cover member at the weakened sections. An insert is formed in situ of the filler material in an opening in a restraint member and the insert is engaged during initial inflation of the airbag to displace the filler material so as to stress the outer cover member at the weakened sections thereof for separating a hidden door segment from the cover member as the airbag is inflated and solely in response to such inflation prior to deployment of the airbag into the passenger compartment.

Abstract: A method for manufacturing decorative features in situ in a base layer of cast plastic material includes the steps of providing a heated mold tool with a selectively heated surface in the form of a desired decorative feature; depositing a covering of thermoplastic material in the recessed surface and heating the recessed surface to partially fuse the thermoplastic material on the recessed surface to form segments of plastic corresponding to the desired decorative feature; dumping excess thermoplastic material from the heated mold tool; thereafter spray coating the mold at the recessed surface to stabilize the location of the partially fused material in the recessed surface; reheating the mold tool to partially remelt the retained stabilized segments and thereafter depositing a base layer of thermoplastic material across the full surface of the mold and reheating the mold to bond the retained stabilized segments to the base layer and cooling and stripping the mold to form a finished plastic shell having a deco