Abstract: An improved injection molding apparatus for molding snap-on, thermoplastic air bag covers is provided including a plurality of wedge-shaped outboard mold parts slidably mounted on bearing surfaces of a plurality of gibs which are removably mounted to a central wedge all nested together within a central recess in the lower mold half in retracted positions of the outboard mold parts. Each of the outboard mold parts has a clip member-defining surface for forming front and rear sections and a snap-on groove of its corresponding clip member of the air bag cover. Each outboard mold part is in sliding contact with its respective gib during its entire sliding movement between its retracted and fully extended positions.

Abstract: A mold for use in a gas-assisted injection molding system includes an adjustable overflow pin assembly which includes a conical stack of shims which are removably secured to an ejector pin to move therewith within a conically-shaped spill cavity flow-coupled by a secondary runner to an article-defining cavity of the mold. The mold also includes a blocking pin assembly which together with the adjustable overflow pin assembly are mounted on an ejector plate to move therewith between extended and retracted positions of the ejector plate. The blocking pin assembly includes a blocking pin which is slidably fit within the second mold half to move relative to the ejector plate between an extended blocking position to block the flow of molten plastic through the secondary runner and a retracted position to allow the flow of molten plastic through the secondary runner and into the spill cavity.

Abstract: A method and apparatus for making a thermoplastic air bag cover having a hidden tear seam. A molten thermoplastic is injected into a mold cavity of a mold having a shape defining the air bag cover. An insert having a shape defining the tear seam is extended into the mold cavity before the molten plastic completely solidifies. The resulting air bag cover is cooled to a temperature beneath the softening point of the plastic. The completed air bag cover is then removed from the mold. The thickness of the air bag cover at the tear seam is within a range of 0.2 to 0.4 millimeters.

Abstract: A method and apparatus for making a thermoplastic air bag cover having a hidden tear seam. A molten thermoplastic is injected into a mold cavity of a mold having a shape defining the air bag cover. An insert having a shape defining the tear seam is extended into the mold cavity before the molten plastic completely solidifies. The resulting air bag cover is cooled to a temperature beneath the softening point of the plastic. The completed air bag cover is then removed from the mold. The thickness of the air bag cover at the tear seam is within a range of 0.2 to 0.4 millimeters.

Abstract: A natural wood-covered plastic part, such as a vehicle part, and a method of manufacturing same. The natural wood-covered plastic part includes a one-piece thermoplastic elastomeric body or structural substrate and a plastic-wood composite of a thermoplastic material compatible with the thermoplastic elastomer of the structural substrate. The plastic-wood composite and the plastic part are placed together at a bonding station. A bottom contact surface of the plastic-wood composite bonds with a front contact surface of the structural substrate between the contact surfaces thereof. The plastic-wood composite and the structural substrate may be bonded together in one of several ways, such as injection molding, compression molding and thermal or chemical bonding.

Abstract: A relatively flexible thermoplastic air bag cover assembly having a switch and method of manufacturing same is provided including a thermoplastic electromagnetic material which forms welds between front and back panels of the assembly. The welded front and back panels define a switch pocket therebetween to hold the switch such as a membrane-type horn switch therein. The welds occupy a relatively small amount of surface area yet provide strong polymer-to-polymer linkages between the front and back panels, thereby enlarging the effective switch activation area on the outer surface of the front panel. The welds are located very close to the switch pocket without damaging the switch during manufacturing. The bonds provided by the welds between the front and back panels are strong enough to prevent the switch from exiting the switch pocket during air bag deployment.

Abstract: A plastic molded, air bag cover mountable in a snap-on fashion onto a retaining member or rim fixedly secured within an automotive seat is provided. The snap-on air bag cover includes a front cover panel including an outer peripheral portion adapted to overlie an air bag container and a close-out ring sewn to an outer fabric of the seat. Resilient clip members extend from the outer peripheral portion toward the retaining member. Each clip member has an extending snap-on groove defined therein adapted to cooperate with the retaining member for affixing the air bag cover to the automotive seat. The clip members are connected to the outer peripheral portion such that the resilient clip members are permitted to pivotably travel away from each other in opposite directions allowing the retaining member to enter and abuttingly engage the snap-on groove thereby retaining the air bag cover on the automotive seat.

Abstract: A thermoplastic air bag cover is provided having a plurality of domes formed on its front cover which enclose switches of at least one multifunctional unitary switching module. Preferably, a pair of unitary multifunctional switching modules are provided and corresponding raised domes in the front cover sealingly enclose and protect the switches thereof and also serve as switch activation mechanisms. In a separate embodiment of the invention, a coupling mechanism is provided for both mechanically and electrically coupling the first and second unitary switching modules together in order to facilitate assembly of the resulting air bag cover.

Abstract: A relatively flexible thermoplastic air bag cover is provided including a front panel wherein switch activating members enhance activation of a membrane-type switch located at a switch location area of the front panel. This feature provides pressure points which enhance activation of the membrane-type switch. The switch activating members are located on the rear inner surface of the cover in one embodiment and, in another embodiment, on the upper surface of a back plate which provides a hollow compartment for the switch. The switch activating members can be integrally formed in the shape of small circles, ribs, raised dots, X's, etc.

Abstract: An air bag module (12) includes an inflator (20), a canister (24) which contains the inflator (20), and an air bag (18). The air bag module (12) further includes a retainer assembly (26) which contains the air bag (18) in an uninflated condition. The retainer assembly (26) includes a pair of retainers (210,212) that are fastened together with an edge portion (192) of the air bag (18) retained between the retainers (210,212). The retainer assembly (26) and the canister (24) are fastened to each other in an assembled relationship in which an inlet opening (196) in the air bag (18) is aligned with an outlet opening (112) in the canister (24). The retainer assembly (26) and the canister (24) snap together into a mechanically interlocked condition when they are moved into their assembled relationship. The inflator (20) and the canister (24) also snap together into a mechanically interlocked condition when the inflator (20) is moved into the canister (24).

Abstract: A snap-on air bag cover for use with an air bag container having a retaining member. The snap-on air bag cover includes a plastic front cover adapted to directly enclose an uninflated air bag. A pair of plastic side panels are connected to opposite sides of the front cover. A resilient clip member extends from each of the side panels, the clip member having an extending snap-on groove defined therein adapted to cooperate with the retaining member for affixing the air bag cover to the air bag container. The pair of side panels are connected to the front cover such that the side panels and resilient clip members are permitted to pivotably travel away from each other in opposite directions allowing the retaining member to enter and abuttingly engage the snap-on groove thereby retaining the air bag cover on the air bag container. A horn switch assembly is disposed in and substantially fills at least one compartment formed at the inner surface of the cover.

Abstract: A plastic air bag cover is provided with an integrated light source and is adapted for use within a passenger compartment of a vehicle. The light source is mounted on a base plate and a front plate cooperates with the base plate to seal the light source therebetween. The front plate is provided with indicia capable of transmitting light therethrough, the indicia represent graphical information wherein light transmitted through the indicia causes an information-bearing image to be projected into the passenger compartment through a window formed in a front panel of the air bag cover. The light source may be an emissive display such as an electroluminescent or thin film electroluminescent display. Alternatively, the light source may be a flat panel display such an emissive display or an electroluminescent display.

Abstract: The surface of a clay model is laser scanned to obtain a set of laser scan data. The scan data provides X, Y and Z values of the part. The raw scan data is then preferably edited to smooth, filter, and pre-process it for further use. A first algorithm implemented at an engineering workstation is used to create a first set of equations which represent a three-dimensional surface of the model from the edited set of scan data. A second algorithm utilizes known wire frame data for the part model to compute a second set of mathematical equations. The first set of equations and the second set of equations represent surface(s) and characteristics of the model in a recorded format usable by CAD-based systems to facilitate part design and tool construction. A third algorithm generates an NC tool path data from the first and second set of equations. The NC tool path data may be utilized at a machining center to cut a production part mold, or a direct reproduction of the model.

Abstract: A plastic air bag cover is provided having an integrated occupant-sensing sensor module adapted for use in a vehicle occupant-sensing system. The sensor module includes a base plate and either a single occupant-sensing sensor (i.e., a transceiver) or a sensor pair (a transmitter and a separate receiver) mounted on the base plate. The sensor module receives a first signal which is transmitted through a window in the front panel of the air bag cover. In one embodiment, the window is formed adjacent the front panel. In turn, the sensor generates a second signal for use by the occupant-sensing system to prevent the air bag from being deployed.

Abstract: A thermoplastic air bag cover having a unitary multifunctional domed switching module is provided wherein the domes are integrally formed with a front plate of the switching module to seal and protect switches of the switching module. The domes extend through a window formed in a front panel of the cover and the domes include indicia formed on outer surfaces thereof to indicate a particular automotive vehicle accessory and its function to be controlled thereby. In one embodiment, a membrane-type horn switch is coupled to the unitary switching module at a rear inner surface of the front panel. Both the unitary switching module and the membrane-type horn switch are secured at an inner surface of the front panel of the air bag cover by first and second coupled back plates.

Abstract: An automotive air bag cover is provided having a decorative applique fastened thereto. The air bag cover is manufactured from plastic and includes a front cover adapted to enclose an uninflated automotive air bag. The front cover includes an inner and outer surface. Side panels are further provided and are connected to and extend from the front cover. The decorative applique is fastened to the outer surface of the front cover. Seams are provided for permitting the air bag to inflate and exit the front cover. The decorative applique is fastened to the front cover adjacent the seams in a non-overlapping fashion such that the decorative applique does not interfere with exit or inflation of said air bag.

Abstract: A snap-on air bag cover for use with an uninflated air bag container including a retaining member, the snap-on air bag cover comprising, a plastic front cover adapted to directly enclose the uninflated air bag container, a pair of plastic side panels connected to opposite sides of the front cover, a resilient clip member extending from each of the side panels, the clip member having an extending snap-on groove defined therein adapted to cooperate with the retaining member for affixing the air bag cover to the air bag container, wherein the pair of side panels are connected to the front cover such that the side panels and resilient clip members are permitted to pivotably travel away from each other in opposite directions allowing the retaining member to enter and abuttingly engage the snap-on groove thereby retaining the air bag cover on the air bag container.

Abstract: A plastic air bag cover for use in an automobile, the air bag cover comprising, a front cover adapted to enclose an uninflated automotive air bag, the front cover having inner and outer surfaces defining a first thickness therebetween and a decorative indicia defined on the outer surface of the front cover and a break seam defined in the inner surface of the front cover for permitting the air bag to inflate and exit the front cover, the break seam further defining a break pattern and having a first wall, a second wall and a break wall connecting the first and second walls, the break wall having inner and outer surfaces defining a second thickness therebetween, wherein the second thickness is less than the first thickness, the break wall and first and second walls are visually imperceptible when viewing the front cover outer surface, and the break seam is substantially non-coincidental with the decorative indicia.

Abstract: An automotive air bag cover is provided having a decorative applique fastened thereto. The air bag cover is manufactured from plastic and includes a front cover adapted to enclose an uninflated automotive air bag. The front cover includes an inner and outer surface. Side panels are further provided and are connected to and extend from the front cover. The decorative applique is fastened to the outer surface of the front cover. Seams are provided for permitting the air bag to inflate and exit the front cover. The decorative applique is fastened to the front cover adjacent the seams in a non-overlapping fashion such that the decorative applique does not interfere with exit or inflation of said air bag.

Abstract: A snap-on air bag cover for use with an air bag container having a retaining member. The snap-on air bag cover includes a plastic front cover adapted to directly enclose an uninflated air bag. A pair of plastic side panels are connected to opposite sides of the front cover. A resilient clip member extends from each of the side panels, the clip member having an extending snap-on groove defined therein adapted to cooperate with the retaining member for affixing the air bag cover to the air bag container. The pair of side panels are connected to the front cover such that the side panels and resilient clip members are permitted to pivotably travel away from each other in opposite directions allowing the retaining member to enter and abuttingly engage the snap-on groove thereby retaining the air bag cover on the air bag container. A horn switch assembly is disposed in and substantially fills a pair of compartments formed at the inner surface of the cover.