Abstract: A composite plastic article is provided which includes an improved boss for fastening the article to a supporting structure. The composite article includes a decorative outer skin co-molded to a reinforced foam layer. The foam layer is formed from a foaming resin such as polyurethane in an exothermic reaction. The boss is formed as a part of the foam layer and protrudes through the insert. A metallic fibrous material such as steel wool is molded into the boss to give the boss added structural integrity and to remove heat generated during formation of the boss and foam layer to thereby reduce cracking of the boss and localized blistering and delamination of the outer skin. A method for making such a boss is also provided.

Abstract: A drying apparatus including a booth having a ferris wheel mounted therein, and a blower and heater mounted on the booth. The ferris wheel includes three pairs of rotatably mounted radially extending arms, a support plate pivotally mounted on the distal ends of the arms, adapted to hold a part which is loaded and sprayed with a waterbased clearcoat at a first position, indexed to a position directly below the blower and heater for approximately one minute to be impinged by warm air, then indexed to a third position to continue drying, before returning to the first position to be replaced by another part. The heater is a plurality of ceramic disc heater units in one embodiment and an electric duct heater in an alternate embodiment.

Abstract: Vacuum metallizing substrates having both vertical and horizontal surfaces occurs by directing metal from two remote sources by thermal evaporation. One source is connected horizontally below the object to depose metal vertically toward the object to the horizontal surface thereof. The second source is connected vertically to the object to depose metal horizontally toward the object to the vertical surface thereof. A vacuum chamber contains a rotating carousel supporting the objects with the sources located fixedly within the chamber to perform the thermal evaporation.

Abstract: A skin or shell is disclosed 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: A transport system is provided which includes a conveyor having an alternate forwardly and reversely driven rollers. A carrier disposed on the conveyor has a pair of spaced skis which engage the forwardly rotating rollers to move the carrier along the conveyor. A friction belt disposed over a pair of pickup rollers on the carrier engages the reversely rotating rollers on the conveyor to provide a rotational drive for use on the carrier. An alternative embodiment is also disclosed which provides rotational motion on the carrier only when the carrier is moving along the conveyor.

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 partial 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 rear shelf module for a passenger car includes a plurality of transverse reinforcing channels forming electrical cable ducts or air conditioning ducts through the module for locating electrical conduits for connection to rear light and sound system components located respectively in fore and aft facing housing segments formed integrally of the rear shelf module and for directing heating, air conditioning and ventilation air to the rear passenger compartment.

Abstract: A vehicle door system (10) for reducing the impact of a person against the door when the vehicle undergoes a side impact. The system includes an inner door panel (14) mounted to a door frame (12) in spaced apart fashion. The inner panel (14) is mounted to the frame (12) with a plurality of shock absorbing fasteners (20) which absorbs some of the kinetic energy transmitted from the door frame to the person.

Abstract: A method of molding automotive interior trim parts wherein a block of a predetermined thickness and area of a suitable grade of fiber or other suitable insert material is pressed into a molten vinyl shell during the latter's curing cycle. The fiber block or insert becomes fused to the vinyl shell and may expand to approximately three times its original thickness to serve as the backing and mounting insert for the finished two-component interior trim part.

Abstract: An airbag canister and sensor and gas deployment unit attached to the lap belt portion of an automotive three-point seat belt system, wherein the lap belt portion is attached at one end thereof to the sill at the base of the center pillar. The airbag components are positioned adjacent the outside edge of the front seat, and intermediate the hip portion of the occupant and the vehicle door. When the seat belt is not in use, the airbag components assume a stowed position along side the center pillar intermediate the base and the usual upper shoulder belt dispenser, providing for easy entry and egress by the operator or passenger.

Abstract: An interior trim product has an opening therein formed to overlie an air bag restraint assembly housed in the trim product. The air bag restraint assembly includes a canister for generating gas to inflate 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. First and second substrates formed in the interior trim product and on the door support two hook and loop fastener strips each of which is connected to one of the substrates to form a tamper proof connection for holding the door in place prior to air bag deployment.

Abstract: A cover assembly for an air bag restraint system has a smooth outer skin with a backing layer of foam located between the outer skin cover and a retainer member. The retainer member is located above the outlet of an air bag casing and includes a plurality of flaps therein each having a pointed end located in a hidden position beneath the foam and outer skin cover and at a point generally centrally of the outlet of the casing. Each of the flaps is connected to the retainer member by integral hinge segments in the retainer member. When the air bag is inflated, it will cause the segments to pivot outwardly about the hinge segments to pierce both the foam layer and the outer skin and peel them apart so as to form a multi-sided opening through the cover assembly for deployment of the air bag.

Abstract: A constant force air cushion arrangement for side impact protection, including a plurality of air cells mounted on the inner door panel. A tapered stem is integrally molded on the inner surface of each cell so as to extend toward the inner door panel. An orifice opening, which may have a diaphragm mounted therein, is formed in a wall of each cell adjacent the distal end of the tapered stem. In the event of a side impact of a predetermined force, the stem enters the orifice opening, either directly, or by bursting through the diaphragm in response to the relative velocity between the door and an occupant to progressively restrict the orifice opening and, hence, the volume of air forced out through the orifice by a progressively decreasing velocity between the door and the occupant.

Abstract: A side impact protection apparatus for use on the inner panel of a vehicle door. The apparatus is a cushion including a hollow flexible skin having an inner wall secured to the inner panel, flexible ties between the skin and the inner wall or low density open-celled foam to prevent the skin from bulging, a rupturable diaphragm-covered orifice or a coupling having an extrudable elastomeric plug mounted therein connected to the inner wall, and a medium of air under pressure or hydraulic fluid or water or a polygel contained in the cushion and adaptable to discharge by rupturing the diaphragm or extruding the elastomeric plug when subjected to impact by the vehicle occupant in the event of a high force side impact against the vehicle.

Abstract: A method of molding utilizes an apparatus (10) for molding a thin-wall plastic shell which 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 bellows member (34) having a gasket (42) about the end thereof is extended from the opening (18) to perfect a sealed passageway between the opening (18) and the periphery (22) of the mold surface (20).

Abstract: A bolster formed of suitable cushioning material attached to the lap belt portion of an automotive three-point seat belt system, wherein the lap belt portion of an automotive three-point seat belt system, wherein the lap belt portion is attached at one end thereof to the sill at the base of the center pillar. The bolster is sized and positioned so as to contact the outside edge of the front seat and the hip portion of the occupant, spaced apart from the vehicle door, providing cushioning between the occupant and the door. When the seat belt is not in use, the bolster assumed a stowed position along side the center pillar intermediate the base and the usual upper shoulder belt dispenser, providing for easy entry and egress by the operator or passenger.

Abstract: Evaporation boats utilized in the vacuum metalizing process are categorized based on evaporation characteristics thereof to match similar boats for the metalizing process. Power is supplied to the evaluation boat and the period of time required for the evaluation boat to reach a predetermined temperature is monitored. This period of time is indicative of the evaporation rate of the boat during the metalizing process and is used to categorize and match boats as super slow, slow or fast.

Abstract: A vehicle steering wheel has a decorative panel concealing a storage compartment for an inflatable air bag. The panel has a covering which comprises a backing plate having a U-shaped cut line framing the storage compartment and defining a cover door having a hinge line connecting the ends of the cut line U. An inner layer of foam is interposed between the backing plate and an outer skin layer. The skin has a peripheral groove outlining the door and comprises a hinge section overlaying the hinge line and a weakened tear seam line overlying the cut line. The groove is cut through at the bottom along the tear seam line but not along the hinge section. Inflation of the air bag will force the door outwardly, fracturing the foam layer along the tear seam line to swing the door away from the opening about the hinge section to enable deployment of the air bag outwardly of teh panel. The cuts in the panel layers can be made before or after a molding process.

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 bellows member (34) having a gasket (42) about the end thereof is extended from the opening (18) to perfect a sealed passageway between the opening (18) and the periphery (22) of the mold surface (20).

Abstract: An apparatus for practicing a method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products. The apparatus includes a mold with a recess therein and a plug being supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part. A heater device directs 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 on which thermoplastic material is cast 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.