Abstract: A thermoformable acoustical mat composition having reduced quantities of ethylene vinyl acetate and elastomers and increased filler concentrations. The composition includes an intimate blend of 5% to 30% of an asphalt constituent; 4% to 15% of an elastomer binder constituent; 50% to 80% of a filler constituent and 1% to 8% of an ethylene co-polymer constituent. A method of melt mixing and extrusion forming thermoformable acoustical mat compositions is also provided.

Abstract: A cover member for an air bag installation, includes a shaped cap-link member of soft urethane molded directly onto and in covering relation to a pair of thermoplastic, L-shaped, angle members, the urethane adhering to the thermoplastic and operating to prevent inadvertent release of the urethane during deployment of the bag.

Abstract: An exterior rearview mirror assembly that is attached to the side wall of the door of a vehicle having a mirror shell housing mounted on the side wall and a mirror mounting bracket mounted in cantilever fashion on the side wall. The mirror mounting bracket preferably comprises a body having a triangular shape cross section with first and second side walls forming a cavity, the cavity opening to a third side. A plurality of truss walls are interposed between the first and second side walls of the mirror mounting bracket and are constructed and arranged to increase the damping characteristics and natural frequency of the mirror mounting bracket.

Abstract: An adjustable rear view mirror for an automotive vehicle adapted to be mounted on a door and comprising a housing including a mounting flange at one end and an opening adjacent the other end, an end bracket in the housing, a mirror and a mounting mechanism supporting the mirror in the opening of the housing. The mounting mechanism comprises an adaptor connected to the mirror, a cup, a sleeve and a retainer. The adaptor includes a spherical portion having a slot. The cup is mounted on the end bracket, or alternatively, on the housing and engages the outer spherical portion of the adaptor. The sleeve has a rib on its outer surface and spaced from the rib is a groove on the inner surface of the sleeve. The sleeve engages the inner surface of the adaptor and is positioned so the rib is received in a slot of the adaptor. The retainer engages the inner surface of the sleeve and has a rib received in the groove of the sleeve. A spring yieldingly urges the retainer on the cup.

Abstract: An exterior rear view mirror assembly having a housing with a passage for directing a mixture of ambient air and conditioned air over the exterior surface of a side window of a vehicle. A mounting structure attached to the housing has a grille adjoining the interior of the vehicle and connected to a duct. Conditioned air is drawn from the vehicle interior through the grille to the duct which is in communication with the passage.

Abstract: A method for forming a fiber web and fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: A process for making a substantially even thickness fascia part. The fascia part is prepared by placement of a plastic powdered material into an enclosed mold, heating and agitating the mold for distributing the plastic powder on the mold surfaces to provide a substantially even thickness fascia part on the molding surface. The mold includes first mold surfaces for defining critical portions of the mold which correspond to the desired portions of the mold for forming the finished shape of the part by melting of the plastic powder to a uniform film along the surface. The mold also includes second mold surfaces defining non-critical portions of the mold where it is undesirable for plastic filming to occur.

Abstract: A method for forming a fiber web and fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: An improved window gasket assembly and the apparatus and associated method for reaction injection molding such assemblies, as well as other molded articles, are disclosed. The gasket is preferably integrally molded from an elastomeric material such as urethane onto a substantially transparent window panel. The gasket and window assembly can then be mounted and secured directly to a vehicle body panel opening, for example, with adhesives, thereby eliminating the need for discrete mechanical fasteners. In a preferred embodiment of the invention, an improved aftermixer and gating apparatus includes a mixing body in which a flowable multi-constituent molding material is separated into a number of generally serpentine mixing passageways and reunited in a common mixing cavity before being conveyed through a fan-gate passageway to the mold cavity.

Abstract: A process for insulating a rotational casting mold for use in a casting process for making a substantially even thickness fascia. The fascia is prepared by placement of a plastic powdered material into an enclosed mold, heating and agitating the mold for distributing the plastic powder on the mold surfaces to provide a substantially even thickness fascia part on the molding surface. The mold includes first mold surfaces for defining critical portions of the mold which correspond to the desired portions of the mold for forming the finished shape of the part by melting of the plastic powder to a uniform film along the surface. The mold also includes second mold surfaces defining non-critical portions of the mold where it is undesirable for plastic filming to occur.

Abstract: A process of molding a single-piece article by placing a resin body on a divider of a resin supply container containing different resins, fitting the resin supply container against a mold surface, engaging the resin body between the divider and the mold surface defining two discrete mold chambers, rotating the resin supply container and mold surface to contact the different resins against the mold surface, and heating the mold surface to simultaneously set the different resins and the resin body into a single-piece article.

Abstract: An improved molded hinge assembly is disclosed and is particularly adapted for pivoted vehicle window applications. The assembly allows for the pivotal mounting of a vehicle window in a window opening in a vehicle body panel while requiring little or no bonding or other affixation of the window gasket or hinge assembly to the outer surface of the window panel. Futhermore, the present invention provides a molded hinge assembly that is relatively simple and inexpensive to manufacture and to install in a vehicle window application. Such a hinge assembly can also be manufactured by reaction injection molding techniques from multi-constituent materials, such as urethane, for example, which allows molding at relatively low pressures to prevent or minimize glass breakage and provides for secure bonding and sealing between the window gasket and the window panel.

Abstract: An improved window gasket assembly with an integral living hinge member and the apparatus and associated method for reaction injection molding and bonding such assemblies, as well as other molded articles, are disclosed. The gasket is preferably integrally molded from an elastomeric material such as urethane, and at least a portion of which is simultaneously bonded onto at least one substantially transparent window panel. The gasket and window assembly can then be mounted and bonded or secured directly to a vehicle body panel opening, for example, with adhesives, thereby eliminating the need for discrete mechanical fasteners, with at least one window panel being hingedly and pivotally attached to said vehicle body panel.

Abstract: An improved window gasket assembly and the apparatus and associated method for reaction injection molding such as assemblies, as well as other molded articles, are disclosed. The gasket is preferably integrally molded from an elastomeric material such as urethane onto a substantially transparent window panel. The gasket and window assembly can then be mounted and secured directly to vehicle body panel opening, for example, with adhesives, thereby eliminating the need for discrete mechanical fasteners. In a preferred embodiment of the invention, an improved aftermixer and gating apparatus includes a mixing body in which a flowable multi-constituent molding material is separated into a number of generally serpentine mixing passageways and reunited in a common mixing cavity before being conveyed through a fan-gate passageway to the mold cavity.

Abstract: The plastic molded article is produced by heating a mold by contact with a preheated salt bath. The salt bath is readily maintained at a uniform temperature and is self-insulating for energy efficiency. A noncontact infrared sensor monitors the mold cavity temperature while in the salt bath, and the mold is removed from the bath when the proper mold temperature is reached. A charge of plastic powder is introduced into the mold by clamping the mold to a powder slush box with the mold cavity confronting the opening of the box. The mold and box are then simultaneously rotated to pour the plastic charge into the mold. The plastic charge forms a skin on the cavity surface and additional plastic material may be built up to provide additional thickness. The mold and box are then separated; the mold is then postcured and cooled, whereupon the finished article may be removed from the mold.

Abstract: A method of forming a fibrous web useful for compression molding stiff, board-like structural substrates for panels by thoroughly intermixing a blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: An improved window gasket assembly and the apparatus and associated method for reaction injection molding such assemblies, as well as other molded articles, are disclosed. The gasket is preferably integrally molded from an elastomeric material such as urethane onto a substantially transparent window panel. The gasket and window assembly can then be mounted and secured directly to a vehicle body panel opening, for example, with adhesives, thereby eliminating the need for discrete mechanical fasteners. In a preferred embodiment of the invention, an improved aftermixer and gating apparatus includes a mixing body in which a flowable multi-constituent molding material is separated into a number of generally serpentine mixing passageways and reunited in a common mixing cavity before being conveyed through a fan-gate passageway to the mold cavity.

Abstract: The multifunction steering wheel controls the operation of vehicle functions or devices such as headlights, windshield wipers, cruise control, and so forth, using a transmitter receiver pair to convey information relative to the operation of the devices between the rotatable steering wheel and stationary steering column. In particular, the transmitter receiver pair may take the form of an optoelectronic infrared transmitter disposed on the steering wheel member and a matching infrared receiver positioned on the steering column within the field of elimination of the transmitter.

Abstract: The multifunction steering wheel controls the operation of vehicle functions or devices such as headlights, windshield wipers, cruise control, and so forth, using a transmitter/receiver pair to convey information relative to the operation of the devices between the rotatable steering wheel and stationary steering column or between an anti-rotating control pad and the steering column. In particular, the transmitter/receiver pair may take the form of an optoelectronic infrared transmitter disposed on the steering wheel member and a matching infrared receiver positioned on the steering column within the field of elimination of the transmitter. If desired, a second transmitter/receiver pair conveys information in the opposite direction to confirm that the function or device is properly responding to control.

Abstract: A fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.