Abstract: A steering wheel mounted air bag cover door (10) includes a horn switch (20) disposed on its outside surface (16) for actuating a vehicle horn (40) in response to the application of a predetermined horn actuating force to the cover door. The horn switch (20) is spaced apart laterally from the tear seam (18) on the cover door (10). A cover band (22) extends over and conceals the horn switch (20), the cover band also being spaced apart laterally from the tear seam (18). The cover band (22) includes a removable attachment feature (26) whereby the cover band may be removed easily from the cover door (10) to replace the horn switch (20). An adjustment feature (28) enables one to adjust the distance between the cover band (22) and the cover door (10) to prevent pinching of the horn switch (20).

Abstract: A reinforced vinyl shell comprises a two layer construction for covering air bag doors that open through the shell when an air bag is deployed. The reinforced vinyl shell includes a first layer of unreinforced vinyl and a second layer is fused to the first layer and is formed of a vinyl material mixed with reinforcing fibers. Such fibers are randomly dispersed in the vinyl and may be comprised of fillers, such as glass, recycled RIM, or recycled vinyl. Other thermoplastic castable materials may be used in place of the vinyl.

Abstract: A separate door assembly with an outer shell, a layer of backing foam and a rigid substrate for covering an inflatable air bag system of a supplemental restraint system to protect the occupant of a vehicle, the separate door seats within an opening in an interior trim structure of a vehicle and is attached to the interior trim structure so that the whole door assembly can separate from the interior trim product during air bag deployment without delamination of the outer shell from the layer of backing foam.

Abstract: A system for controlling the liquid pressure for a liquid cutting dispenser includes an intensifier for producing a predetermined constant pressurized liquid through a conduit to the cutting dispenser. A plurality of reducing dispensers are connected to the conduit and selectively controlled to reduce the pressure from the predetermined pressure of liquid. By actuating different combinations of reducing dispensers having different jewel sizes, variable pressures are obtained. The selection and duration of the reducing dispensers are programmed into memory along with a path a robot is to follow to allow automated cutting with variable pressures.

Abstract: A process for producing a motor vehicle bumper includes the steps of depositing chopped glass fibers (19) and a curable binder (24) to a center section (38) of a preform (11) that is retained on a preform screen (14) by a vacuum draw from a suction fan (15). A ratio of shredded structural reinforced injected molded plastic (23) and glass fiber (19) is sprayed to form end sections (41) and flanges (39) of the preform (11) along with binder (24). The preform (11) is then cured on the screen (14).

Abstract: An inflatable neck support is a U-shaped collar comprising an inflatable bladder and a decorative cover that provides a wide range of styling choices. The inflatable neck support is attached to a seat back or a head restraint in a variety of ways so that it is easily adjusted by the seat occupant to meet the seat occupant's comfort needs. When not in use, the inflatable neck support is deflated and stored in a number of convenient ways.

Abstract: A process for producing a preform (44) includes pretreating roving by submerging it in a tank (18) and cooling the binder (20) on the glass fibers before the glass fibers are chopped. The fibers and solidified binder are then chopped and deposited onto a preform screen (32). Heat is applied to soften the binder that is on the chopped glass fibers and cooled to set the binder and form the preform on the screen.

Abstract: A method for manufacturing an automobile trim component includes the step of coextruding a plastic unfoamed material and foamed material into a multilayer parison, which is thereafter blow molded to a desired form. After the layers are cured, the article is removed from the blow mold and sectioned into multilayer skin halves, and one skin is placed in an injection mold. The core resin, either thermoplastic or thermoset in nature, is then injected into the injection mold and onto the skin, and then compresses the resin against the skin to produce a shell comprising a resin core layer, intermediate foam layer, and decorative outer layer.

Abstract: A retractable speaker assembly for an automobile is disclosed which includes a housing containing at least one loudspeaker, a first actuator for selectively moving the housing between a retracted position and an extended position, and a second actuator for rotating the housing sideways so that the speaker can be directed toward the left or right side of the automobile interior.

Abstract: A gasketing device for forming a molded interior trim component for a vehicle utilizes a flexible planar gasket compressed between mold halves to prevent foaming material from entering the gasket area. The gasket is adapted to be secured to a structural insert and has a flexible peripheral edge that seals against the inside surface of a bezel on the insert. The gasket extends through the opening defined by the bezel to seal against a skin shell. The method includes mounting the gasket on the insert. The insert and gasket are placed on a mold half with an opposing mold half having a skin shell thereon. A foaming formulation is placed between the skin shell and insert and allowed to foam about the gasket to secure the insert to the skin shell. The product is removed, the skin shell over the gasket cut and peeled away to form an opening in the shell dimensioned smaller than the dimensions of the peripheral edge of the gasket.

Abstract: A high gloss color finish for a plastic article is formed by coating and curing a colored primer layer (12) onto a plastic substrate (10). A light transmissive basecoat (14) is applied and cured onto the primer layer (12) to form a substrate (10) with a colored surface. Indium islands (20) are vacuum deposited onto the basecoat (12) to a thickness up to 100 Angstroms to form a visually macroscopically continuous layer (21). The island layer (21) is etched to remove smaller sized islands. A transparent topcoat (24) is applied onto the basecoat and indium islands and cured in place.

Abstract: A hollow core instrument panel provides the look and feel of a urethane filled instrument panel without the associated disadvantages. A rigid retainer substrate provides a skeletal superstructure. A hollow shell applique is attached to the retainer substrate for providing a decorative exterior. The hollow shell applique includes a resilient upper wall, a lower wall, contoured to matingly engage the retainer substrate, a forward end wall and a rearward end wall. One or more ribs may be provided intermediate the forward and rearward end walls. The forward and rearward end walls are hook-shaped for mechanically clamping about the edges of the retainer substrate. Vent holes prevent pressure build-up within the hollow shell applique.

Abstract: A self piercing cover assembly for concealing an air bag restraint system in a vehicle passenger compartment has a plurality of retractable cutter blades that are attached to the underside of an invisible door beneath the instrument panel by leaf springs. When the air bag inflates, it pushes the cutter blades out against the bias of springs to cut through the instrument panel at several locations along the front edge of the door making it easier for the door to swing open. The cutter blades retract under the action of the leaf springs so that the cutting edges are below the surface of the cover assembly to protect against contact with the cutting edges after the air bag collapses.

Abstract: An apparatus and process for manufacturing multiple thin walled hollow shells for parts such as automobile door panels, arm rests, and instrument panels from thermoplastic plastisol includes a pair of plastisol charge boxes each forming a separate compartment and members for joining the charge boxes with an open ended mold. The mold has a divider rib thereon that is inaccessible by straight vertical engagement of a seal assembly on the divider. An indexable divider wall is operatively connected between the charge boxes so that the divider wall can be selectively extended and retracted at an angle with respect to the vertical and against the mold at the divider rib thereon for allowing separation of the casting surfaces having different colors fixed thereon and the subsequent fusing of the casting surfaces to one another at the divider.

Abstract: A self piercing cover assembly for concealing an air bag restraint system in a vehicle passenger compartment has a retractable cutter blade that is attached to the underside of an instrument panel next to front end of an invisible door beneath the instrument panel. When the air bag inflates, the cutter blade is pushed up by a deflector shield against the bias of springs and cuts through the instrument panel at several locations making it easier for the door to swing open. The deflector shield is then bent and broken off or deformed by the inflating air bag to provide a shield for protecting against contact with the sharp edges of the cutter blade. The shield and cutter blade retract under the action of the springs so that the shielded cutting edge is below the surface of the instrument panel to provide primary protection against contact with the sharp edges of the cutter blade after the air bag collapses.

Abstract: An apparatus (10) for molding a thin-wall plastic shell includes a powder box (12) and a mold box (14). The powder box (12) is positioned to an operative position wherein an opening (18) in the powder box (12) is brought in proximity to the mold surface (20) of the mold. A contoured selective charge application panel (36) has a gasket (30) about the end thereof and the selective charge application panel (36) is extended vertically from the opening (18) at variable heights to perfect a sealed surface at the opening (18) and the periphery (22) of the mold surface (20) to mask vertically extending waste surfaces (14a, 14b).

Abstract: An aluminum object is manufactured by a process including chromate conversion coating of the aluminum object; sequentially applying a primer coat to the outer surface and thereafter applying a dielectric substrate basecoat; vacuum metallizing a corrosion prone metal, namely indium, on the dielectric substrate basecoat to form "islands" of the indium that are top coated with a clear resinous layer to encapsulate and insulate the islands, one from another. The indium islands are less than one thousand angstroms thick and have an average diameter of less than three thousand angstroms. The island structure is etched following the growth of the metal as it is deposited between the nucleation stage and the stage of channelization of formation of an electrically conductive film. The etchant is selected to clear channels between island structures to improve adhesion of a dielectric resinous top coat to the dielectric substrate by order of magnitude to adhesion to the islands.

Abstract: A cover for an air bag unit is disclosed having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and comprising a material having properties different than that of the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with an opening therein that have the tear seam pattern. The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Abstract: A bright trim article is manufactured by a process including applying a primer coat material to the outer surface of a raw part and thereafter applying a dielectric substrate basecoat by rotation and spray painting to prevent orange peel; thereafter vacuum metallizing a corrosion prone metal, namely indium, on the dielectric substrate basecoat to form "islands" of the indium that are etched following the growth of the metal as it is deposited after the nucleation stage and the stage of channelization but before the formation of an electrically conductive film; thereafter applying a clear resinous topcoat material by rotating the base-coated part and spraying the resinous topcoat material to prevent an orange peel surface while filling the channels and covering the islands to encapsulate and insulate the islands, one from another.A preferred application of this invention is the manufacture of trim parts for the automotive, plumbing and building industries.

Abstract: The modular dual mug and cup holder is allowed access upon sliding opening movement of the holder out of a housing, such as an armrest, into an open position. In a closed position, the holder slides into the housing disallowing access thereto. The holder includes a sliding member having a center planar divider with arcuate cutouts therein, and a pair of arcuate cup members producing generally circular cavities with the center support for holding containers or cups. In the closed position, the arcuate cup members are pivoted in overlapping orientation with one another and with the center planar divider for compact insertion within the housing. The holders slide outwardly automatically upon release of a push-push latch and a biasing spring.