Abstract: A method of forming a skin-foam-substrate type structure particular suitable as an automobile trim component. The method comprises supplying a polymer resin containing a chemical foaming agent and including metal particles capable of inductive heating, that is positioned between a polymeric skin and substrate, followed by inductive heating to cause foaming of the polymeric resin. The foamed polymer resin adheres to the skin and substrate.

Abstract: Methods for forming a TPE-skinned composite include forming a skin layer having at least one surface and having a thermoplastic elastomer and an adhesive promoting agent; providing a foam layer; and forming the foam layer onto the said surface of the skin layer to form the TPE-skinned composite. Optional additives such as an organo-silane compound may be added to further improve the adhesion between the skin layer and the foam. The present disclosure also provides a TPE-skinned composite including a skin layer having a thermoplastic elastomer present in an amount of greater than 90 wt. %; and an adhesive promoting agent present in an amount of from 0.5 wt. % to 10 wt. % based upon the total weight of the skin layer.

Abstract: A fastening system comprising a second fastener fastened to a first fastener; the first fastener comprising a hollow housing having a side-wall and a top-wall; a first aperture formed in the side-wall and in the top-wall of the hollow housing, the first aperture configured for entry of the second fastener during fastening of the second fastener and first fastener; a second aperture formed in the side-wall of the hollow housing; a beam formed in the side-wall between the first aperture and the second aperture, the beam attached at opposing ends to the side-wall; the beam blocks the first aperture to inhibit separation of the second fastener from the first fastener through the first aperture; and the beam is configured to be deformed during fastening of the second fastener to the first fastener.

Abstract: A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

Abstract: A method of providing interior trim for a motor vehicle comprising forming a first interior trim article providing a first interior trim level, wherein the first article comprises a first article decorative covering overlying a first article cushion member and a first article substrate; and forming a second interior trim article having a base structure comprising the first interior trim article; wherein the second interior trim article provides a second interior trim level different from the first interior trim level; wherein the second interior trim article comprises a second article decorative covering and a second article cushion member overlying the base structure; wherein the first article decorative covering includes an elongated channel; wherein the second article decorative covering comprises a plurality of decorative covering segments joined at a joining seam; and wherein the joining seam is located in the elongated channel.

Abstract: A method of forming a blow molded plastic article wherein the article comprises an airflow conduit, comprising: providing a first sheet of insulation material located on a insulation carrier; providing a blow molding mold including two halves and having a molding surface defining a molding cavity to form the article; locating the insulation carrier between the two halves of the blow molding mold; transferring the first sheet of insulation material from the insulation carrier to the blow molding mold; introducing an extrudate of thermoplastic composition between the two halves of the blow molding mold; closing the blow molding mold; forming the extrudate to a shape of the mold cavity of the blow molding mold to form the article; and bonding the extrudate to the first sheet of insulation material as the extrudate is being formed to the shape of the mold cavity.

Abstract: The present invention relates generally to the manufacture of vehicular floor mats using recycled content. In particular, the present disclosure identifies the ability to form extrudable floor mats suitable for interior vehicular applications where the recycle content includes recycling of selected amounts of a laminate of crosslinked polyolefin foam and thermoplastic polyolefin resin.

Abstract: A textile structure is provided which comprises a backing of at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier. A method of providing a slip resistant covering to overlie a floor pan carpet of a motor vehicle is provided comprising overlying the carpet with an accessory mat having an underlying backing comprising at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier, and wherein the underlying backing of the accessory mat is configured to be in direct contact with the floor pan carpet.

Abstract: A component of a motor vehicle comprising a photoluminescent interior member formed of a plastic composition, wherein the plastic composition comprises at least one polymer and a plurality of additives comprising at least one photoluminescent material and at least a first ultraviolet protector, wherein the at least one photoluminescent material absorbs electromagnetic radiation in a first ultraviolet range of an electromagnetic spectrum, and thereafter emits electromagnetic radiation in a visible radiation range of the electromagnetic spectrum, and wherein the first ultraviolet protector is an ultraviolet absorber, wherein the ultraviolet absorber absorbs electromagnetic radiation in a second ultraviolet range of the electromagnetic spectrum and does not absorb electromagnetic radiation in the first ultraviolet range of the electromagnetic spectrum.

Abstract: A decorative article is provide which comprises a substrate including a front side, a rear side and a perimeter side, with the perimeter side of the substrate including at least one perimeter corner of the substrate. An elongated slot is formed in the rear side of the substrate. The elongated slot includes at least one slot corner and at least one slot corner extension, with the slot corner extension extending from the slot corner to the perimeter corner of the substrate. A decorative covering which covers the front side, the perimeter side and a peripheral region of the rear side of the substrate, with the decorative covering being located in and terminating the slot including the slot corner and the slot corner extension to conceal a perimeter edge of the decorative covering.

Abstract: The present disclosure relates to the production of molded products containing recycled content, and more particularly polyurethane foam which includes polyol recovered from chemical recycling of polyurethane foam scrap, which polyol has been treated to optimize viscosity and/or reactivity characteristics.

Abstract: A three piece fastener is provided for attaching two layers, e.g. a floor mat for a vehicle to a floor carpet which may then stabilize the mat relative to the carpeting. The three components may connect together through a combination of mechanical connections to provide a relatively simple and cost effective solution to floor mat retention.

Abstract: A three piece fastener is provided for attaching two layers, e.g. a floor mat for a vehicle to a floor carpet which may then stabilize the mat relative to the carpeting. The three components may connect together through a combination of mechanical connections to provide a relatively simple and cost effective solution to floor mat retention.

Abstract: An acoustic insulator for a motor vehicle is provided comprising a mass providing an acoustic barrier and a spring providing an acoustic absorber overlying the mass. The mass comprises a first acoustic mass layer underlying a second acoustic mass layer. The first acoustic mass layer is provided by a thermoplastic sheet having a thickness in a range of 0.5 mm to 1 mm. The second acoustic mass layer is provided at one or more localized areas formed in place on a backside surface of the first acoustic mass layer to increase an overall thickness of the mass at the one or more localized areas. The spring layer is formed in place on a backside of the second acoustic mass layer and the backside of the first acoustic mass layer.

Abstract: The present disclosure relates to the production of molded products containing recycled content, and more particularly polyurethane foam which includes polyol recovered from chemical recycling of polyurethane foam scrap, which polyol has been treated to optimize viscosity and/or reactivity characteristics.

Abstract: A molding apparatus to trim a molded product which comprises an outer member and a substrate member is disclosed, with the molding apparatus comprising a first mold half and a second mold half operable together to define a mold cavity to form the molded product therein and edge-wrap at least a portion of the substrate with the outer member; a trimming device operable to trim the outer member at the edge-wrapped portion of the molded product as the first mold half and/or the second mold half move in an opening direction relative to one another; and the trimming device comprising shearing means, the shearing means comprising a pair of cooperating shearing edges with one shear edge provided by the first mold half and the other shear edge provided by the second mold half.

Abstract: The present invention relates to surfacing material which may emit radiation in response to exposure to a given light source. Such surfacing material may be polymeric based, and e.g., fiber based, and may be used in relatively low-light areas, including low-light areas as applied to vehicular applications. The fiber-based or molded materials may emit radiation in response to exposure to a selected light source and may be used in relatively dimly lit areas. The materials may also provide a visible contrast to other objects located adjacent their surface which do not emit radiation. Optical brighteners and luminous particles may be included in the materials to make them luminous.

Abstract: An energy absorber for a vehicle includes an elongate member having one or more corrugated sections, the corrugated sections including a plurality of channels wherein the channels include a generally planar front wall and a pair of spaced apart vertically extending side walls, and one or two at least partial end walls. The elongate member further includes a base section extending between channels and one or more flanges that may extend from the base. The energy absorber may be tuned for a desired impact and be located between a bumper beam and a fascia at the front or rear end of a vehicle to provide low speed impact protection.

Abstract: The present disclosure relates to the production of molded products containing recycled content, and more particularly polyurethane foam which includes polyol recovered from chemical recycling of polyurethane foam scrap, which polyol has been treated to optimize viscosity and/or reactivity characteristics.

Abstract: A textile structure is provided which comprises a backing of at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier. A method of providing a slip resistant covering to overlie a floor pan carpet of a motor vehicle is provided comprising overlying the carpet with an accessory mat having an underlying backing comprising at least a first plurality of fibers and a second plurality of fibers, wherein the first plurality of fibers have a first fiber denier and the second plurality of fibers have a second fiber denier different than the first fiber denier, and wherein the underlying backing of the accessory mat is configured to be in direct contact with the floor pan carpet.