Abstract: A releasable latch (50) is provided for a door assembly (14) having an outer skin member, a foam backing member, and an inner door member. The door assembly conceals an airbag restraint system having a housing, an airbag and a gas generator producing an inflatant for inflating the airbag for deploying the airbag through the door assembly. The releasable latch has a closed U-shaped end that is press fit in an open U-shaped end on a retainer member on the housing to hold the door assembly in a mating relationship to interior trim parts. The inner door member is engaged during initial inflation of the airbag to displace the door assembly so as to bend the inner door member at a hinge joint between the outer cover member and the interior trim part and the press fit between the closed U-shaped end and the open U-shaped end provides easy opening of the door assembly as the airbag is inflated.

Abstract: A mold apparatus for forming parts by reacting foam precursors in a mold cavity part closed by a cover has a mold breaker assembly including a member for holding a molded foam product in the mold cavity part as the cover is removed for part demolding. The member defines a slide for movement of the cover with respect to the mold cavity part to break adhesion of the cover from the top of the molded part while the molded part is firmly held in the mold cavity part. The mold breaker assembly includes a lift handle on the cover which is used to open the cover once the adhesive forces are broken so as to expose the molded part for demolding without scraping against the mold cavity part.

Abstract: A method for forming a plastic coating for a foam molding insert or retainer member includes the steps of preforming an insert member having openings therethrough; partially sealing the openings and/or the perimeter edge of the insert member with protuberances formed on a conforming buck; completely sealing the openings and/or the perimeter edge by spraying polymeric material against the insert and the protuberances only in the vicinity of the hole and the perimeter edge to form seals without covering the insert with a film wrap; curing the seals to provide a leak proof patch which prevents foam leakage through the insert during a foam molding process.

Abstract: An apparatus for forming a return flange on the belt trim portion of a vehicle door panel includes a door panel support with a movable backing member to back a belt trim portion when the panel is clamped in place. The apparatus further includes a heater mechanism and a flange former mechanism on the machine which 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: A cover assembly for an air cushion restraint has a smooth cover with a layer of foam connected between the cover and a load bearing insert for covering a housing for an airbag and a gas generator which generates an inflatant for the airbag for deploying the airbag; three cutters are pivotally connected to the insert member to cut an insert cover member from the insert and to pierce the smooth outer cover member during inflation of the airbag so as to form a self-piercing cover assembly which will be cut to form a three sided opening through the cover assembly through which the airbag is deployed; the cutters are actuated by an insert cover member support system which will operate the cutters as the airbag is inflated to cause cutting edges on the cutters to pierce the smooth outer cover member. The cutters are recessed within the cover assembly to avoid incidental contact with the cutting edges prior to deployment.

Abstract: 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 method for testing foam formulations for the quantitative measure of the effects of formulation and/or process variable changes on some kinds of surface problems of a molded part caused by different degrees of imperfection or voiding underneath the part surface. The molded part can be single component or composite, solid or foamed. One example of the surface problem is the so-called "measles or cellulite" problem observed on the vinyl surface of a vinyl/foam composite due to the voids or rattiness within the foam. To accomplish this result, the mold has various sized, spaced apart, aligned openings formed in each of the front and rear walls of the mold, but with the centers thereof at different elevations in the respective front and rear walls. Removable rods inserted through the aligned mold wall openings produce longitudinal openings through the part which is molded around the rods, permitting the effect thereof on the surface of the molded part to be evaluated.

Abstract: A method for recovering vinyl and urethane foam from composite plastic articles for recycling by granulating the article to form separated mixed components destaticizing the separate mixed components to prevent static during cling between foam particles and vinyl shell particles; and directing the destaticized particles through a vibrating fluidized bed to separate the vinyl shell particles and the foam particles.

Abstract: An inner door panel assembly for a vehicle door is adapted to be connected to an outer door panel to form a space therebetween for a window and a window regulator; the inner door panel assembly is an all plastic composite assembly including an inner covering on the inner surface of a molded plastic substrate. The substrate includes first and second integrally formed hollow boxes thereon faced in the direction of the interior space to absorb side impact energy directed against the side of the outer door panel.

Abstract: A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a prtial recess closed by a removable plug and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part.

Abstract: A cover assembly for an air cushion restraint has a smooth cover with a layer of foam between the cover and a load bearing insert for covering a housing for an airbag and a gas generator which generates an inflatant for the airbag for deploying the airbag; the cover assembly includes a single cutter which has three blade edges of a depth to cut through the layer of foam and smooth cover before a cover insert member is actuated to form a three sided opening through the cover assembly through which the airbag is deployed; the single cutter is pivoted on a retainer insert member as the airbag is inflated to cause cutting edges on the cutter to pierce the smooth outer cover member. The cutter is recessed within the cover assembly to avoid incidental contact with the cutting edges prior to deployment. The cutter is bent to be self-retained following airbag deployment to shield the cutting edges from passenger contact during secondary impacts.

Abstract: A tool for manufacturing the two tone plastic shell includes an electroformed mold (28) having a first surface (29) for forming a front of a shell; a second surface (32) for forming the side edge portion of a shell; and a third surface segment (34) for forming a return flange on a door shell and the third surface segment has a cut-out opening (36) therein and a runout surface (40) providing for entry and removal of a seal and divider wall assembly to seal against a sealing rib (38) in the mold which separates the first, second and third segments into first and second casting surfaces. The divider rib and runout surface are sprayed with thermoplastic material to form a joint between material cast on the first and second casting surfaces and a skin return flap for sealing the cut-out opening.

Abstract: A mold assembly for molding thermoplastic particles into a solid thin shell includes a metal shell having a cavity and including an outer surface exposed to a heat source and further including an inner surface on which thermoplastic material is cast and fused to form a thin layer thermoplastic shell. The heat transfer area of the metal shell is increased by providing a plurality of heat transfer pins connected to the outer surface; each of the heat transfer pins has an extended outside surface area exposed to the heat source for heating the metal shell and each of the heat transfer pins further includes a large diameter head portion which is joined to the metal shell by a capacitive weld nugget formed solely between the large diameter head portion and the outer surface of the metal shell without disrupting the metal shell at surface portions thereof formed between the heat transfer pins.

Abstract: A bumper fastening system for a composite SRIM (structural reaction injected molded) member made up of a core member covered by a reinforced outer cover has a fastening cup connected to the reinforced outer cover by a layer of adhesive material. The fastening cup is a hollow rectangle with a flat end plate which is covered by a layer of adhesive for connection to the composite SRIM or to a metal bumper by spot welds. The hollow rectangle has a depth which will engage it with crush convolutions on frame rails of a vehicle frame. Mating holes in the hollow rectangle and the side rails receive mechanical fasteners for removably attaching the bumper assembly on the frame rails during installation at the automobile assembly plant and for replacement/repair of a damaged bumper.

Abstract: A skin or shell for use in a mold process in which the skin or shell is placed in a mold in which foam precursors are directed onto the skin for reaction thereagainst to form a foam layer thereon; the skin includes integral connector features thereon adapted to be connected to the mold for stabilizing the location of the skin within the mold so as to prevent wrinkling of the skin during the mold process.

Abstract: The apparatus includes a first female mold member defining a mold cavity for receiving a plastic skin or layer. A second mold member or slide is positioned with a surface thereon contiguous with the surface of the mold cavity. The surface of the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. A third mold member, such as a mold core, positions a rigid insert in the mold cavity with an insert surface or edge adjacent the portion of the plastisol skin on the second mold member. The second mold member includes passages for directing fluid pressure against the portion of skin thereon to fold it over the adjacent insert edge. A fourth mold member, such as a mold lid, is movable toward the second and third mold members for pressing the folded-over skin against the insert during foam formation between the skin and insert.

Abstract: A process of separating vinyl skin from a foam backing and recovering the separated components by granulating the plastics composite into small chips, mixing the chips with a quantity of water in a vessel to swell and break the cell structure of the foam at the foam/vinyl interface resulting in flotation of the foam bits and sinking of the heavier vinyl bits. The separated foam is recovered by adding additional water to flow the foam material from the mix vessel. The vinyl is then removed from the bottom of the vessel and the separated components are dried for recycling or improved disposal purposes.

Abstract: Apparatus for stabilizing the location of a skin or shell in a mold for foaming a part includes magnets on the mold adapted to be releasably interconnected to a shell retention and draw bar. The draw bar connects to an integral shell connector. The draw bar is adjustable to pull the shell with respect to the magnets for removing wrinkles from the shell prior to foaming the part.

Abstract: A method of making a foam filled polymer article includes the steps of compressing an expandable foam material (12) and containing the compressed expandable material (12) in a degradable container, such as a polyethylene bag (16). An outer polymer shell (10) is formed while degrading the container (16) therewithin, such as by rotation molding. The shell (10) is filled with the uncontained expandable foam material (12).

Abstract: A process for molding foam products from foam precursors reacted in a mold cavity formed in part by a mold lid and which is covered by a double layer cover to maintain the surface of the lid clean during the foaming process comprising the steps of: providing a double layered cover having four working surfaces; adhering one of the working surfaces to the lid and thereafter closing the tool lid and foaming the part. The lid is opened and the cover and foam part are separated from the mold. The lid is separated from the double layer cover and foam part at a working surface of low strength adhesive; a release sheet of the cover is separated at two other working surfaces to expose a high strength adhesive for connecting the foam part to another member. The double layer cover used for practicing the process includes a foam layer adapted to have one surface thereof bonded to foam material and including a high strength adhesive backing thereon.