Abstract: The invention relates to a sound insulating structure including low-density and high-density layers. The low-density layer has first and second fibrous layers and ranges from 0.5 to 1.5 kg/m.sup.2 in surface density. The first and second fibrous layers are respectively made of first and second thermoplastic synthetic fibers. The first and second fibers respectively have first and second single fiber diameters, each of which diameters is in a range of from 3 to 40 .mu.m, and first and second fiber lengths, each of which lengths is in a range of from 10 to 100 mm. The high-density layer is formed on the low-density layer and is made of an air-impermeable polymer material and has a surface density that is higher than that of the low-density layer and ranges from 1 to 10 kg/m.sup.2. The low-density layer is high in sound-absorption coefficient and at the same time low in spring constant. Therefore, the sound insulating structure becomes substantially improved in sound insulating capability.

Abstract: In a method for molding a laminated assembly comprising a resin core member, and a surface skin member either partly or entirely placed over the surface of the resin core member, the dimensional precision of a part of the surface skin member involving a high rate of extension is improved, and the cushioning property and the surface quality of this part are avoided from being impaired. An approximately molded portion is defined in a part of the surface skin member involving a relatively high rate of extension during the vacuum molding process using a vacuum molding die assembly, and the thus molded surface skin member is mounted on the upper die for mold press forming with a gap defined between the approximately molded portion or an unmolded portion and the associated die surface.

Abstract: In a mold press forming process for integrally molding a resin core member and a surface skin member, prior to the step of forming the resin core member, a surface skin member is retained between an upper die half and a lower die half by a surface skin retaining frame which consists of a fixed segment and a moveable segment. The moveable segment is moved vertically relatively to the fixed segment to better adapt the surface skin member to a three-dimensional parting line between the upper and lower half dies. When mounting the surface skin member onto the surface skin retaining frame presents a planar mounting surface, the mounting work is facilitated, and automated mounting devices can be used without any problem.

Abstract: In an automotive upholstery component including a trim main body and an ornamental sheet mounted on a selected part of the surface of the trim main body, the ornamental sheet is attached to the trim main body without using a bonding agent so that the fabrication steps may be reduced in number, the working environment may be improved, and the design characteristics of the product may be enhanced. A door trim main body is placed on an upper die for pressing which is equipped with a welder upper electrode, and the ornamental sheet is placed on the lower die for pressing which is equipped with a welder lower electrode. High frequency electric current of a prescribed voltage is applied across the upper and lower electrodes so that the ornamental sheet may be attached to a prescribed part of the surface of the door trim main body 20 over the entire area of the ornamental sheet, and the use of a bonding agent may be thereby abolished.

Abstract: An automotive interior component such as an automotive door trim comprising a main body integrally combining a resin core member and a surface skin member by a mold press forming process and an attachment member attached to a part of the main body, in which the attachment member is attached to the main body by way of connecting parts of the resin core member during the process of mold press forming. The connecting part may consist of an extension of the resin core member which is pushed out of openings provided in the surface skin member and adhered to the attachment member. Alternatively, the connecting part may consist of parts of the resin core member into which engagement pawls provided in the attachment member, in particular, an attachment core member thereof are penetrated through the surface skin member. In either case, solidification of the connecting parts completes the attachment of the automotive door trim.

Abstract: A bonding device and bonding process for a surface skin member of a vehicle interior component which can reliably fold back and secure a peripheral part of a surface skin member onto the reverse surface of a core member without involving any positional deviation between the core member and the surface skin member even when the width of the peripheral part is small. A block of elastic material is used for a lower die for mounting a surface skin member in a bonding station, and slide bars are arranged around the lower die in a peripheral part folding back station disposed adjacent to the bonding station for provisionally shaping the peripheral part of the surface skin member. Further, vertically moveable bars are arranged around an upper die for mounting the core member thereon for pressing the peripheral part of the surface skin member which has been provisionally shaped against the reverse surface of the core member.

Abstract: An automotive interior component such as an automotive door trim comprising a main body integrally combining a resin core member and a surface skin member by a mold press forming process and an attachment member attached to a part of the main body, in which the attachment member is attached to the main body by way of connecting parts of the resin core member during the process of mold press forming. The connecting part may consist of an extension of the resin core member which is pushed out of openings provided in the surface skin member and adhered to the attachment member. Alternatively, the connecting part may consist of parts of the resin core member into which engagement pawls provided in the attachment member, in particular, an attachment core member thereof are penetrated through the surface skin member. In either case, solidification of the connecting parts completes the attachment of the automotive door trim.

Abstract: To allow smooth access to such elements as operating knobs for power window switches and a door lock switch provided in a unit panel in the night time lighting condition, the entire surface of an escutcheon panel mounted on the unit panel is defined as a switch operating part for an illuminating lamp which illuminates the elements to be accessed. The illuminating lamp may be lighted up for a prescribed time period to illuminate the escutcheon panel when the switch operating part is touched so that unnecessary consumption of electric power may be avoided. The escutcheon panel may be made of at lease semi-transparent plastic so that light from an illuminating lamp placed behind the escutcheon panel may be transmitted through the escutcheon panel. Alternatively, the element to be accessed such as a switch knob mounted on the escutcheon panel may be made of at lease semi-transparent plastic so that illuminating light may be transmitted therethrough.

Abstract: A bonding device and bonding process for a surface skin member of a vehicle interior component which can reliably fold back and secure a peripheral part of a surface skin member onto the reverse surface of a core member without involving any positional deviation between the core member and the surface skin member even when the width of the peripheral part is small. A block of elastic material is used for a lower die for mounting a surface skin member in a bonding station, and slide bars are arranged around the lower die in a peripheral part folding back station disposed adjacent to the bonding station for provisionally shaping the peripheral part of the surface skin member. Further, vertically moveable bars are arranged around an upper die for mounting the core member thereon for pressing the peripheral part of the surface skin member which has been provisionally shaped against the reverse surface of the core member.

Abstract: In a method and device for mold press forming involving distribution of molten resin within a mold including a plurality of valve gates, deformation of the product and generation of excessive burrs and voids are prevented by accurately distributing a prescribed amount of resin material to each valve gate by detecting the amount of molten resin supplied from an injection unit and controlling the opening timing and period of each valve gate. The amount of molten resin supplied from the injection unit can be conveniently evaluated by detecting the displacement of an in-line screw used in the injection unit. By providing a metering arrangement for each of the valve gates, the molten resin can be even more accurately distributed to each of the valve gates.

Abstract: In a method and device for combining a resin core member and a surface skin member at the same time as molding the resin core member into a desired shape, air and reaction gas trapped in the die cavity is removed through air vent pieces embedded in the die surfaces of the upper and lower dies so that a laminated molded article with a favorable appearance free from creases can be obtained. The air vent pieces may be either porous or provided with minute slits so that air and gas may be removed but the resin material may not seep through.

Abstract: A method for fabricating an automotive trim which is mounted with an ornamental member, in which an ornamental member which is not molded by any preliminary forming process is secured on a surface of a door trim main body with a bonding die set so as to closely follow a complicated surface profile of the door trim main body, extraneous parts of this ornamental member is cut by a thermal cutting blade attached to the bonding lower die, and the peripheral edge of the ornamental member is finished by a pressure bar.

Abstract: A method for manufacturing automotive interior component parts, including the steps of: positioning a skin layer, having a back liner cushioning layer, on a mold surface of an upper mold with the cushioning layer facing downward; extruding a sheet of semi-molten thermoplastic resin material serving as a core layer directly onto a mold surface of a lower mold; clamping together the upper and the lower mold in such a manner that the core layer and the skin layer are bonded together with the cushioning layer interposed therebetween. Since the core material is sufficiently soft when it is bonded to the skin layer and the cushioning layer provides a buffer for the press pressure and a barrier against the infiltration of the soft core material, the skin layer is given with a very smooth surface even when it is made of porous material such as fabric. Additionally, since the core material is directly extruded onto a core surface, the pressure and the temperature involved the press forming process may be low.

Abstract: In this resilient multi layered member, there are provided as laminated together: a surface skin layer, formed of PVC resin powder made into a gel, on the outside side of the resilient multi layered member; a foam material layer, formed from foamed PVC resin powder, the outer side of which is adhered to the inner side of the surface skin layer; a cushion material layer, the outer side of which is adhered to the inner side of the foam material layer; and a substantially stiff core material layer, the outer side of which is adhered to the inner side of the cushion material layer, on the inside side of the resilient multi layered member. There may be further included an adhesive layer by means of which the outer side of the cushion material layer is adhered to the inner side of the foam material layer. The cushion material layer may be formed from urethane foam, or from non woven fabric, which may be a felt material, and may have a density greater than about 200 grams per square meter.

Abstract: A shaft which pivotally supports a sun visor is formed with flat surfaces at longitudinally staggered positions and on opposite sides of the shaft, a spring is attached to the visor proper which has flat portions for engaging the flat surfaces so that a "snap action" is provided only when the visor is rotated into close proximity of a home position wherein the flat portions of the spring clamp down flatly on the flat surfaces. When the visor is rotated away from this home position the distortion of the flat portions of the spring produces a reaction which induces sufficient friction between the shaft and the spring to hold the visor in any given selected position.

Abstract: An upholstery fixing device consists of a bracket having a holdfast suspended therefrom with bendable or flexible straps. In use the bracket is riveted to the back of a trim board, and the holdfast is pushed into an associated aperture of an inside panel of a car door. Then, the bendable straps can be yieldingly bent to automatically reduce any misalignment between a fixed bracket (and hence its holdfast) and an associated aperture of the inside panel of the car door, thus facilitating the fixing of the upholstery to the inside panel of the car door in exact registration.