Abstract: A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold an

Abstract: For automotive interior trim molding assemblies having a vinyl skin shell, a reinforcement insert, and an intermediate reaction type polyurethane foam composition, a vinyl skin shell which has a gasket-type peripheral edge formed thereon for abutting cooperation with the reinforcement insert to prevent leakage of the foam therepast during the foam reaction period in a reaction mold. The gasket-type peripheral edge is formed on the otherwise thin shell by a tear edge, against which plastisol builds up in a substantially triangular cross section during the shell molding period in a heated slush mold.

Abstract: In a process for masking a part subjected to a high pressure washing cycle between the applications of two or more paint coats, the improvement comprising the steps of: spray coating on a prepainted part a washable masking material which is cuttable when set to form a nonwicking edge; self adhering the spray coating and cutting it along a paint line to form a nonwicking mask edge which prevents paint leakage or the trapping or washing solution between the masking material and part and leakage of such trapped washing solution onto a subsequently painted surface. The process includes the step of cutting and cleanly peeling a portion of the masking material from the part following the drying of the sprayed mask to expose part of the prepainted surface; at least one subsequent washing and drying of the masked part; and at least one subsequent painting of the exposed prepainted surface.

Abstract: A pour hole closure for use with an injection foam molding system including a mold assembly having a pour bushing leading to a reaction chamber. A cylinder having a slightly oversized plastic plug extending downwardly therefrom is normally positioned above the pour bushing in the mold assembly. The cylinder is pivotally movable away from its normal position against the force of resilient means. A pour head and nozzle assembly is adapted to move into engagement with the cylinder to move the latter while attaining a position wherein the nozzle is positioned above the pour bushing. The nozzle is lowered to engage the top edge of the pour bushing for injection of foam material into the reaction chamber.

Abstract: A water jet trim head simulator has the same configuration and dimensions as a cutting or trim head nozzle on a water jet apparatus for trimming workpiece scrap. The simulator is used to guide a robot arm of the apparatus into various multi-axes trim head positions during a teaching mode of operation of the controller for the apparatus. The simulator includes mounting means for connection to the robot arm. The simulator further includes tracking means including a hollow body connected to a fiber optics bundle for directing light from a source to an objective lens for focusing a spot of light on a premarked trim path point on a master workpiece to establish one of a plurality of spatial points to be taught into the controller. The simulator further includes a feeler gauge for physically positioning the simulator with respect to the workpiece to assist the alignment of the light beam to its focused point on the workpiece.

Abstract: An armrest for a door of an automotive vehicle, including a molded shell having a substantially flat top wall portion, an interior shelf portion parallel to the flat top wall portion, a plurality of vertical ribs supporting the shelf portion, and a plurality of abutment ribs intermediate an inner edge of the shelf portion and the flat top wall portion. A back plate is integrally connected to the free end of the flat top wall portion via a living hinge. A foam slab or block is slip fitted into the pocket formed by the flat top wall portion, the shelf portion and the abutment ribs, and retained therein by the closure of the back plate against the free end of the shelf portion.

Abstract: The apparatus includes a first female mold member defining a shaped mold cavity for receiving a plastisol layer or skin. A second mold member is pivotally disposed on the female mold member between an open and closed position. In the open position, the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. An insert is positioned in the mold cavity by a third mold member such as a mold lid on which the insert is releasably retained. After the insert is positioned in the mold cavity, the second mold member is pivoted toward the mold lid to fold the skin portion thereon over and against an edge of the insert. The skin is folded adjacent the pivot axis of the second mold member. Foam can then be introduced and cured between the skin and insert.

Abstract: A method and apparatus for manufacturing a composite article by use of a mold core and a cavity block and wherein a skin and insert are placed in the mold cavity and foam precursors are poured into the mold cavity to complete the article includes a process in which a series of part replicas are formed and used to cast thermally stable liners that are carried by the mold core and mold cavity. The thermally stable liners have low melt temperatures and can be reused and recast following wear during the molding process. The liners are made from material which has low shrinkage and expansion rates to define a mold assembly that will produce repeatable parts.

Abstract: A method for forming finished coverstocks includes automatically heating and indexing slightly overlapped rough seams of coverstock segments with respect to a single thermoforming tool that automatically opens and closes to vacuum fold the rough seams interiorly of the tool and thereafter the folds are pinched to form a finished styling line on the class A surface of the coverstock. An apparatus is provided in which a single thermoforming tool has relatively moveable mold parts that shape the coverstock and include an expandable joint line configured to fold the rough seams and further including slide members responsive to closure of the mold parts to provide space to accommodate the fold for pinching it off with respect to the class A surface. The product of the invention includes multiple coverstocks with finished styling lines formed by pinched off folds on the hidden side of the coverstock.

Abstract: A method for heating a plurality of molds for casting heat fusable thermoplastic material each of the molds having casting surfaces and each of the molds having outer mold profiles which differ and wherein the molds are moveable into a mold chamber including the steps of providing a hot air distributor with different tube length profiles thereon; advancing a selected mold into the heating chamber and indexing the distributor to selectively match the outer profile of a selected mold with a selected tube length profile and directing hot air through the selected tube length profile for uniformly raising the temperature of the selected mold and casting heat fusable thermoplastic material in the heated mold to cause the heat fusable thermoplastic to adhere to the casting surface.

Abstract: A pour mold includes two parts one of which forms a mold cavity and the other of which forms the lid for the mold cavity; the lid includes a retractable pilot pin and vacuum cups for positioning a mold insert within the mold cavity automatically upon lid closure. The pilot pin loosely pilots the insert in the mold as it closes and as the vacuum cups pull the insert toward the lid during such closure. The vacuum cups hold the insert against the lid continuously during foam injection, foam reaction and cure and as the lid is separated from the mold cavity part so as to automatically remove the finished part from the mold when the lid is separated therefrom.

Abstract: A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance.

Abstract: A retainer mold for forming foamed automotive articles, particularly instrument panels, after a thin vinyl skin shell has been mounted in the mold. The mold includes a plurality of die block assemblies mounted in recesses formed in a surface of the mold cavity. Each die block assembly includes a plate member secured in the recess, and a die block slidably mounted within controlled limits on the plate member, and adapted to be covered by the shell and to be moved as required to prevent wrinkling or bridging of the portion of the shell extending between adjacent die blocks.

Abstract: An electrical force motor and servovalve combination has a rotary spool directly coupled to the motor shaft without requiring a rotary-to-linear motion convertor; the rotary spool is configured to have a cruciform metering section that cooperates with a flow sleeve having ports and slots configured to produce four-way flow patterns in a reduced length and volume valve package.

Abstract: The apparatus includes a first female mold member defining a shaped mold cavity for receiving a plastisol layer or skin. A second mold member is pivotally disposed on the female mold member between an open and closed position. In the open position, the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. An insert is positioned in the mold cavity by a third mold member such as a mold lid on which the insert is releasably retained. After the insert is positioned in the mold cavity, the second mold member is pivoted toward the mold lid to fold the skin portion thereon over and against an edge of the insert. The skin is folded adjacent the pivot axis of the second mold member. Foam can then be introduced and cured between the skin and insert.

Abstract: The apparatus includes a first female mold member defining a mold cavity for receiving a plastisol 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 water jet trim head simulator has the same configuration and dimensions as a cutting or trim head nozzle on a water jet apparatus for trimming workpiece scrap. The simulator is used to guide a robot arm of the apparatus into various multi-axes trim head positions during a teaching mode of operation of the controller for the apparatus. The simulator includes mounting means for connection to the robot arm. The simulator further includes tracking means including a hollow body connected to a fiber optics bundle for directing light from a source to an objective lens for focusing a spot of light on a premarked trim path point on a master workpiece to establish one of a plurality of spatial points to be taught into the controller. The simulator further includes a feeler gauge for physically positioning the simulator with respect to the workpiece to assist the alignment of the light beam to its focused point on the workpiece.

Abstract: An improved mold assembly which has a cavity mold part and a cover which form a space into which foam precursors are poured and the cover carries a mold insert which is bonded to the foam formed in the mold space; the cover carries a pour spout and a seal for preventing foam leakage from the space wherein the improvement comprises: means including a pour hole and a rotatable tube extending through said pour hole for defining a pour spout having an inboard end located within the space when the mold assembly is closed; seal means in surrounding sealing relationship with said inboard end of said rotatable tube; and means operative when the cover is closed and when the tube is located in the pour space for holding the insert within a desired variation of a designed location in said space and for holding the insert against said seal means to prevent foam leakage through the pour hole.

Abstract: Apparatus and a process for manufacturing multiple color thin walled hollow shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a powder box divider to form two or more compartments in a powder charge box and means for joining the chrage box divider end-to-end with a mold separation edge on an open-ended heated mold for separating the mold into two or more sections; each compartment of the charge box has a different color powder. The charge box and mold are joined and then are rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resulting shell of cured material.

Abstract: A mold assembly for manufacturing composite plastic products includes a mold cavity part and a lid, which is joined to form a cavity for foam precursors. The precursors expand in the cavity in a known manner to fill the cavity with a suitable layer of foamed material, such as foamed urethane. The mold cavity supports an exterior shell and the lid supports an insert for reinforcing a finished composite product. A sleeve is integrally formed on the preformed shell and it in turn is located within an access port formed through wall of the cavity part to define a slideway for receipt of a pour head extension. The extension is selectively clamped and unclamped with respect to the shell sleeve by an inflatable seal clamp which is formed as an annular ring with a pressurizable passage connected to a source of selectively applied pressure.