Abstract: An injection molded plastic instrument panel P.S.I.R. hidden door milling method including applying a stiff tape, having a hardness greater than a hardness of the plastic instrument panel, to a plastic instrument panel surface to be milled to prevent flexing of the surface during milling. The method may further include milling the surface along a generally width-wise central location of the tape, and removing the tape upon completion of the milling, with the method thereby minimizing burrs along edges of the milled surface. The invention also provides an injection molded plastic instrument panel P.S.I.R. hidden door, and a plastic automotive panel made by method described herein.

Abstract: A passenger airbag module removably connectable to an automotive interior component. The passenger airbag module may include a front bracket engageable with an automotive interior component and a rear connector having a detent or an aperture. A rear bracket may be removably connectable with the rear connector by an aperture or detent for respectively receiving or insertion into the detent or aperture of the rear connector. The rear bracket may be further configured to engage the automotive interior component.

Abstract: A method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes forming at laminate preform, injection molding a substrate layer behind the laminate preform to form a molded automotive interior panel, and forming an opening in the molded automotive interior panel. The method further includes post embossing the molded automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the molded automotive interior panel and a mating subcomponent installed in the opening, thereby producing a tight bezel fit between the molded automotive interior panel and the mating subcomponent installed in the opening. Alternatively, the method includes utilizing a vacuum wrapped automotive interior panel with the embossing step described above. The invention also provides for an automotive interior panel including a tight bezel fit between the panel and mating subcomponents, formed by the aforementioned methods.

Abstract: This invention relates to the field of airbag covers such as are used in the interior of vehicles, and more specifically to an airbag cover having a novel tear seam. The tear seam is adapted to be located over a pair of deployment doors which are located behind the airbag cover. According to one embodiment, the tear seam includes a transverse segment having a width adapted to extend beyond the perimeter of the underlying deployment door. The tear seem also includes a first end segment and a second end segment. The transverse segment extends between and intersects each of the first end segment and the second end segment at locations distal from the perimeter of the underlying airbag door. The first end segment and second end segment each include at least one convex segment proximal the intersection of the first end segment with the transverse segment. Each convex segment is further adapted to be substantially perpendicular to a deployment induced stress pattern in the airbag cover.

Abstract: An apparatus for molding a polymeric multiform skin membrane is provided. The molding apparatus includes a rotatable heated mold envelope having an opening. Additionally the mold envelope has channel members which generally extend lateral of the opening. A feed-stock bucket is provided for holding polymeric work stock. The bucket is moved by a carriage in a direction generally parallel with the channel members of the mold envelope with a first lateral position for loading and a second position closing the opening of the mold envelope. Selectively actuatable clamps are provided for securing the bucket with the mold envelope.

Abstract: A multi element moving vacuum chamber (MEMVC) for rotational casting includes a mold having a predefined shape and an axis of rotation, and a box containing casting material. The MEMVC further includes a first vacuum element mounted to an outer mold surface and a second vacuum element mounted to an outer box surface. The mold and the box are detachably engageable with each other to define an engaged configuration in which air present in an enclosed area defined by the outer mold surface and an inner surface of the first vacuum element, by an inner mold surface and an inner box surface, and by the outer box surface and an inner surface of the second vacuum element, is removed to create a vacuum. Alternatively, the mold and/or the box may be constructed with vacuum loading capability, thereby eliminating the need for the first and/or the second vacuum elements.