Abstract: An insert and method of molding the insert for use with an instrument panel or the like of a vehicle and in which the insert serves as a structural part of a cover for an air bag assembly and is provided with a door which opens upon being impacted by the inflating air bag and in which the door is formed of a flexible plastic material that is bonded in certain areas to the insert and has its plastic material interlocked with the plastic material of the insert in areas which serve as a hinge for the door.

Abstract: A heat insulating panel (20) for a mold tool (14) includes a surface for being mounted onto a section of the mold tool. The panel has an exposed upper surface (29) and a thickness great enough to provide heat insulation sufficient to maintain the temperature at its exposed upper surface lower than the melting temperature of a powder plastic resin (13) that is melted and cured onto the mold tool. Any powder plastic resin on the upper surface remains in powder form during molding such that the powder may be returned to a powder box (12) and be reused. The heat insulating panel (20) has a periphery (21) that covers the entire periphery of the mold tool.

Abstract: An apparatus for interconnection in a helicopter tail rotor control linkage for changing the pitch of the tail rotor blades in response to predetermined inputs is provided. The apparatus comprises a linkage member having a variable geometry, an actuator, and a control unit. In a preferred embodiment, the control unit utilizes a microcontroller to monitor inputs corresponding to ambient air condition and automatically vary the maximum tail rotor pitch so as to provide maximum tail rotor authority over a range of altitudes.

Abstract: A self-drilling stud particularly suited for use in normal weight or lightweight composite deck system where the use of standard weld studs is inappropriate because of the relatively thin material cross-section of the steel support member. The stud is heat treated to a dual-hardness level so that a portion of the stud is capable of drilling the support member and the decking. The remaining portion of the stud remains relatively ductile so that it can withstand and transfer shear loads imposed by shifting of the concrete slab which overlies the decking to the main support members. The stud is a single piece fastener which includes specially formed annular flanges which enhance interlocking between the stud, the concrete slab and support members.

Abstract: A fiber blend for use in friction materials. The fiber contains a blend of a highly fibrillated fiber, such as a fibrillated polyacrylonitrile fiber and a fiber with a high carbon content, such as an oxidized carbon fiber precursor.

Abstract: Disclosed herein is an interferometric-based materials analysis system (10) that employs a novel combination of laser beam shaping and pointing techniques, the use of a low cost, rugged, and compact diode laser (22) as a detection laser, and the use of signal processing techniques that compensate for inherent instabilities and short-term drift in the diode laser. A matched filter processing technique is disclosed for processing interferometrically-obtained data points from a target being analyzed. The matched filter technique is shown to be especially useful for detecting and analyzing Lamb modes within thin targets, such as a silicon wafer undergoing a rapid thermal processing cycle. Also disclosed is a method and apparatus for interferometrically monitoring a target to determine, in accordance with predetermined criteria, an occurrence of a period of time that is optimum for obtaining a data point.

Abstract: A fastening assembly for mounting an inflatable module on a vehicle includes a support structure arranged for securing the inflatable module to a vehicle component for the like, and a coupling member projecting from the support structure and provided with a coupling aperture. Insertable into the coupling aperture is a further coupling element which is secured to the vehicle component and the coupling insertion secures fastening of the module to the vehicle component. In one embodiment, the coupling member includes an arm having a cam-following portion arranged for camming engagement against a coupling tongue on the vehicle component so that the camming engagement produces deflection of the coupling arm until the coupling aperture reversely deflects in snap-action bringing insertion of the tongue therethrough into a wedged, locking position which prevents withdrawal of the inflatable module in the mounted position, for example in the steering wheel hub.

Abstract: A vehicle steering system having a rack and pinion housing, a steering shaft assembly, a driven rack assembly, and an idler lever. The housing has a unitary idler lever mount. The steering shaft assembly has a pinion gear located in the housing. The driven rack assembly is operably connected to the pinion gear and extends out of the housing. The idler lever is pivotally mounted to the housing at the idler lever mount. The driven rack assembly is attached to the idler lever.

Abstract: An underwater thermoplastic pelletizer has an extruding die, and a cutter for cutting a thermoplastic polymer extruded from the die into pellets as the molten polymer is solidified under water that is circulated to cool the extruded polymer and convey the pellets away for collection. The extruding die includes a die plate that is mounted in the face of the die concentric with and opposite the cutter and has a plurality of groups of extruding die holes that are connected in the die to a central main feed passage by separate radially extending distribution feed passages. The die holes in the groups are arranged in circular patterns of uniform radius about a center line intersecting with a circle concentric with the cutter path and the groups are equally angularly spaced about the cutter center line.

Abstract: A wheel cover assembly for covering the wheel of an automotive vehicle has a main body portion formed with a plurality of circumferentially spaced wells having integral cap portions to receive and conceal the lug nuts of the wheel. Locking arms project axially from the wells and embrace the lug nuts to lock the cover member securely on the wheel. Expansion slots are provided between the locking arms of each well to facilitate the disengagement of the locking arms from the lug nuts. A special anti-theft release tool is insertable into the expansion slots forcing the locking arms radially outwardly of one another sufficiently to release the lug nuts and permit the wheel cover to be removed from the wheel.

Abstract: A trim assembly for a vehicle providing energy absorption between a body member and a trim cover and a plurality of energy absorbing pins therebetween that are either permanently plastically deformed upon the cover initially being impacted or that are elastically deformed to absorb kinetic energy as the cover is impacted.

Abstract: A trim molding for a framed opening of a vehicle has an outer flexible skin backed by an energy-absorbing foam core to provide impact protection to the occupants of the vehicle. Imbedded in the foam core is an air duct having an inlet and a plurality of outlets for directing a flow of air out of the duct and on to an adjacent window of the vehicle to clear the window of condensation. The duct yields under the force of impact so as not to detract from the energy-absorbing attribute of the foam.

Abstract: A rivet system (10) locks separate parts (12, 14) of an assembly (13) together on a support fixture (20) with clamping devices (28) and prevents release of the parts (12, 14) from the fixture (20) until a required number of rivets (51) have been placed. A rivet setting tool (50) provides insertion of the rivets (51) between the parts (12, 14), and disposes spent rivet mandrels (62) through a vacuum tube (58) to be sensed. A detector (72) detects the spent rivet mandrels (62) and provides a signal to a controller (100), which measures the length of the mandrel to determine proper crushing or installation of the rivet (51).

Abstract: A fibrous headliner for a motor vehicle passenger compartment is formed with a nonwoven high loft batting of thermoplastic fibers having a low percentage of binder fibers that are activated with heat to establish and hold the desired appearance side contour of the headliner. The batting is needled on both sides to form integral fibrous skin layers wherein the roof side layer is substantially thicker and more dense than the passenger compartment side skin layer. The high density skin layer is then coated with a thermoset resin after the batting has been heated to activate the binder fibers. The hot batting with its resinated high density skin layer is then sandwiched by a blank of scrim stock on this side and a blank of adhesive coated cover stock on the appearance side.

Abstract: A fastener cage for retaining a fastener on a panel comprises a retainer and a collar which sandwich a rigid substrate of the panel and snap-fit together in interconnecting relationship through a hole in the substrate. The retainer retains an anchoring end of the fastener and the collar and the retainer transmit pushing and pulling forces on the panel substrate through extensive areas of the respective inner and outer side of the substrate surrounding the hole. The retainer and collar are formed with a central opening for the insertion of the fastener and a thin inexpensive cover is adhered to the retainer to close the opening therein to prevent the entry of plastic foam that is formed against the inner side of the panel substrate.

Abstract: In accordance with the present invention, a headlamp beam alignment indicating and calibrating device includes a roller element arranged for rolling movement relative to a guide structure, and an indicator for indicating displacement of the roller member resulting from the rolling movement thereof relative to the guide structure. The guide structure is secured to the adjustable beam alignment portion of the headlamp for movement therewith so that any motion of the beam alignment structure results in movement of the guide structure indicated by a relative displacement of the roller element. In a preferred embodiment, the guide structure is an elongate track which is mounted on an adjustable beam alignment reflector wall of the headlamp. The movement of the reflector wall causes the coupled track to move and induce gravitational rolling of a ball in apparent relative displacement along the guide track.

Abstract: A fastener assembly and method for attaching a first member to a second member. The fastener assembly includes a socket member which defines a socket and a stud which includes a head engagable with the socket of the nut. The stud is attached to a first member and the nut is attached to a second member. The assembly is initially attached to the first member by attaching the stud to the first member and then inserting the nut into the second member. When the first member must be removed from the second member, the head of the stud is forcibly disengaged from the socket of the nut. Reattachment of the first member the second member is achieved by forcibly engaging the head with the socket. After the initial insertion, the socket member remains captively retained on the second member.

Abstract: A cover for an air bag unit is disclosed having a patterned tear seam therein defined by a partially bonded material same as the cover material. Apparatus for forming the cover includes a thin shell mold having an inner surface that is heated to melt thermoplastic material cast thereon. A powder box adapted to contain thermoplastic material therein for distribution onto the thin shell mold carries a gasket having a shape corresponding to the tear seam shape. The powder box and gasket are adapted to be connected to the thin shell mold for forming a sealed footprint on the inner surface during distribution of the cast material against heated surface portions of the thin shell mold to form a thermoplastic cover with a narrow gap therein conforming to the desired tear seam pattern.

Abstract: A vehicle bumper system includes a structural reaction injected molded (SRIM) bumper beam that has a hollow body of generally C-shaped cross section and a SRIM reinforcement leaf that is attached to the front wall of the hollow body to increase the damage free impact resistance of the SRIM bumper beam. The reinforcement leaf can be separately molded and bonded to a front wall of the hollow body by a resilient adhesive or molded as an integral part of the hollow body. In the latter case, the integral reinforcement leaf can be solidly attached or it can be attached at the perimeter with its center separated from the front wall of the hollow body by an intervening layer of resilient material. An energy absorber pad of resilient foam material may be attached to a face of the front wall of the hollow body for increasing damage free impact resistance.

Abstract: A car is disclosed having a chassis, an engine, a drive axle assembly, and an engine mounting system. The engine mounting system includes a front engine mount and a rear engine mount. The front engine mount has a first load bearing tie member pivotably connected to the chassis and directly rigidly attached to the engine block. The rear engine mount has a second load bearing tie member directly attached to the drive axle assembly and directly rigidly attached to the engine block. The engine block and two tie members form a rigid unitary assembly.