Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: The method of making a vehicle body panel includes blow molding all or a substantial portion of the vehicle body panel and then securing attachments to openings formed on the blow molded body or to peripheral portions of the blow molded body.

Abstract: A molding method and an impact resistant automotive part such as a bumper beam resulting from the molding method are obtained wherein a thermoplastic reinforced fiber structure at least partially forms a pair of attachment portions of the part and continuously extends between the attachment portions to link the attachment portions. The method includes the steps of providing a plurality of blanks, heating the plurality of blanks, and stacking the plurality of blanks to form a stack of blanks. The stack is then stamped to form the part including the pair of attachment portions spaced a predetermined distance apart. The thermoplastic reinforced fiber structure has tows of fibers wetted by a resin material such as polypropylene. Preferably, the fibers are woven glass fibers.

Abstract: The present invention involves an air bag deployment chute for deploying an air bag through a panel member having a groove. The deployment chute comprises a stationary portion and a door portion. The stationary portion includes a base and a peripheral wall integrally connected thereto. The base has a first surface attached to an inner surface of the panel member and an opening to define an inner periphery of the base. The inner periphery defines an open area which is circumscribed by the groove viewed in plan when the deployment chute is attached to the panel member. The inner periphery is positioned against the structurally weakened area of the panel member so that the groove is supported by the base to prevent inadvertent pivotal movement of the door portion toward the air bag when force is applied on the outer surface of the panel member.

Abstract: A vehicle plastic panel includes a plastic panel body and a speaker grille integrally injection molded with a plastic panel body. The speaker grille has a plurality of sound passages formed therethrough from a front surface to a rear surface, and has a cross-hatched upstanding rib pattern extending from the rear surface.

Abstract: The present invention involves a knee bolster airbag system to dissipate impact energy during an impact of a vehicle in which the system is disposed. The system includes a base which has a first surface disposed toward a vehicle compartment of the vehicle, and a cover having an inner surface attached adjacent the first surface of the base to define a cavity. The cover further has opposite first and second edges, wherein the first edge pivotally attaches the cover to the base about an axis to hinge the first edge of the cover to the base. The system further includes an airbag housing member adjacent which an airbag and a gas source are disposed. The system further includes a tether connected to the base and the cover. The tether allows a predetermined displacement of the second edge away from the base when the airbag is in a deployed state.

Abstract: A removable hardtop including inner and outer roof panels made of molded fiber reinforced sheet molding compound. An integral roll bar is formed in the inner roof panel. A hold down clamp and bracket having horizontal, vertical and transverse flanges mounted on a horizontal edge, vertical surface and transverse surface of a B pillar of a vehicle. A method of molding the inner and outer roof panels and assembling component parts to the inner and outer roof panels is also disclosed.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A shopping cart which is nestable with other conventional shopping carts and has a front storage compartment disposed at a front end oft the cart. The front storage compartment provides for additional storage capacity to the cart without occupying the space of a main compartment of the cart in which the main compartment may contain selected items. The shopping cart includes a front end having upper and lower portions through which the storage compartment is disposed. The front storage compartment is pivotally connected to the shopping cart at the lower portion. The front storage compartment is easily pivoted fore with respect to the front end of the cart to define an open or added storage position. In gathering and nesting the cart with other carts, the front storage compartment is easily pivoted aft with respect to the front end to define a closed or stowed position.

Abstract: A foil-covered automotive interior plastic part including a decorative preform is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a outer surface of a plastic structural substrate at foil-receiving portions of the outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the foil-receiving portions and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but only the side surfaces of the raised design portions which extend above a front surface of the preform. Preferably, the raised design portions represent screw heads.

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

Abstract: A foil-covered plastic part is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a plastic outer surface of a decorative preform at foil-receiving portions of the plastic outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the at least one foil-receiving portion and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but not the side surfaces of the raised design portions. Preferably, the raised design portions represent graphical information.

Abstract: A method is provided for manufacturing a painted plastic component having a badge, emblem or other ornamentation, such as air bag covers having a badge, or wherein the component is the badge itself. The method includes providing a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A motor vehicle trim assembly includes a plastic outer trim panel having an opening, a door for closing the opening, an inner trim panel for storing an uninflated air bag curtain, a hinge for the door and a latch for holding the door in its closed position yet still allow deployment of the air bag curtain through the opening in the outer trim panel. Both the door and the hinge comprise a single injection molded part. The assembly preferably includes a lock for locking the door in its closed position yet also allow deployment of the air bag curtain. The inner trim panel, the latch and the lock all comprise a single injection molded part. The inner trim panel has a conduit portion integrally formed with a solid base wall portion which receives and retains the uninflated air bag curtain as well as an inflator of the system. A gas channel defined by the conduit portion may conduct fluids or pass solid objects such as electric wires through the inner trim panel.

Abstract: The method of making a vehicle body panel includes blow molding all or a substantial portion of the vehicle body panel and then securing attachments to openings formed on the blow molded body or to peripheral portions of the blow molded body.

Abstract: A snap-on air bag cover having enhanced moldability is provided for use with an air bag container assembly including a container having a retaining member and a retaining bracket secured to the container to move therewith. The snap-on air bag cover includes a plastic front panel adapted to overlie an uninflated air bag contained within the container, a plurality of plastic side walls connected to an inner surface of the front panel and resilient locking blocks connected to and extending inwardly from the side walls. Each locking block has an extending snap-on groove defined therein at a surface of the locking block facing the inner surface of the front panel. The locking blocks are adapted to cooperate with the retaining member for affixing the air bag cover to the air bag container. The resilient locking blocks 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: An interior trim panel has an air bag cover for supporting an air bag canister and closing an opening in the interior trim panel. The air bag cover is openable when an air bag is deployed from the cannister. The air bag cover has a deployment door panel, an attachment structure and a hinge structure. The deployment door panel has concealable and exposable sides. The attachment structure, which has hinged and bendable bracket portions, is integrally connected to the concealable side of the deployment door. The hinge structure has first and second hinged portions separated and connected by a tear seam. The hinge structure is integrally connected to the concealable side of the deployment door and attached to the interior trim panel. When the air bag deploys, the tear seam separates and the bendable bracket portion bends, thus allowing the air bag to deploy through the opening in the interior trim panel.

Abstract: A hollow plastic article of a one-piece construction formed from a molten plastic resin by a gas-assisted injection molding system wherein the article is designed in such a way that any gas channel read through is hidden at a “Class A” convex surface thereof. The article includes a hollow body section and a solid wall section which extends downwardly and rearwardly from a front wall of the hollow body section. The solid wall section and the front wall immediately adjacent to the solid wall section define a convex, sink-free, exterior surface of the article to hide any gas channel read through.

Abstract: A vehicle body panel that is formed in part by a blow molding process. Attachments may be assembled to openings formed by cutting off part of a blow molded body. Alternatively, attachments such as seals or seal retainers may be secured to peripheral portions of the blow molded body. The method of making a vehicle body panel includes blow molding all or a substantial portion of the vehicle body panel and then securing attachments to openings formed on the blow molded body or to peripheral portions of the blow molded body.

Abstract: A method and apparatus for making a thermoplastic air bag cover having a visually perceptible tear seam formed by a controlled amount of plastic sinkage during an injection molding process. A molten thermoplastic is injected into a mold cavity of a mold having a shape defining the air bag cover. The mold includes first and second mold halves which form the interior and exterior surfaces of the air bag cover. The first mold half has an outwardly extending projection which cooperates with a smooth inner surface of the second mold half to form the tear seam design in the air bag cover which appears on the outer surface of the air bag cover. The tear seam design formed on the outer surface of the air bag cover is primarily formed because of the near right angles formed at the top edges of the outwardly extending projection which cause the outer surface of the air bag cover to sink to a limited controlled extent during cooling of the plastic beneath its softening point.