Abstract: An instrument trim panel (12) includes a shell (14) made from a flexible plastic material. A textured section (18) is circumscribed by a simulated seam (20). A closed cell plastic block (28) is press fitted behind the textured section. An air pocket (26) is interposed between the block and textured section. A rigid substrate (22) is molded and cured behind the shell (14) and block (28). The air pocket allows the textured section to be deformed to simulate the appearance and feel of a leather applique.

Abstract: An air intake system having a housing and an air filter. The housing has an air inlet, an air outlet, and an air conduiting path therebetween. The path includes changes in air flow direction and velocity at least four times each along the path.

Abstract: A closure for an air bag assembly includes a flexible outer skin and a layer of foam material covering a retainer member that has an air bag deployment opening that is closed by a moveable door. The door overlaps portions of the retainer member to support the door against movement inwardly of the retainer member and allow free hinging movement outwardly of the retainer member for stressing and separating the layer of foam and the outer skin to form a deployment path for the air bag. The moveable door may be retained in the closed position by frangible portions of the retainer member to facilitate manufacture of the closure.

Abstract: A fastener including a sleeve, a stem extending through the sleeve, an integral shear ring adjacent a tail end of the sleeve, and an expander ring between the shear ring and the sleeve tail to facilitate bulbing of the sleeve tail.

Abstract: An integrated compliance electrohydraulic servovalve system connected to a load such as a simulated living being to provide more realistic movement thereto. The system includes a pressure transducer for sensing the pressure appearing at the output of the electrohydraulic servovalve and which is applied to an actuator connected to the load. The pressure as sensed is developed into a corresponding electrical signal which is used as a feed back signal to the drive motor of the electrohydraulic servovalve. The actuator position signal is also provided and is summed with the position command input signal to provide the command signal which is also summed with the pressure signal prior to application to the drive motor. The utilization of the pressure feed back signal provides compliance to the over all system resulting in a realistic movement of the simulated living being.

Abstract: Method and apparatus including a powder box and heatable shell tool are disclosed for forming a thermoplastic automotive air bag cover skin with a lesser strength thermoplastic tear seam strip insert wherein the latter is initially formed with a protruding rib on one side and a pointed ridge on an opposite side. A heat resistant elastomeric transfer socket attached to the powder box interior receives and holds the insert rib and thereby the insert in a prescribed tear seam configuration and then positions the tear seam strip insert against a heated skin defining mold surface on the shell tool when the powder box is joined with the latter. The skin is formed by casting thermoplastic powder from the powder box against the heated mold surface and about the tear seam insert.

Abstract: A molded motor vehicle instrument panel made of a thermoplastic material has an integral air bag deployment door for a passenger side air bag that is defined by a tear seam and is normally retained by an integral flexible mounting/hinge flange to a part of the vehicle structure when the seam is torn by the inflating air bag and wherein this flange then bends to allow the door to swing open to allow deployment of the air bag through an opening in the instrument panel while retaining same to the vehicle structure as the door is then free of the instrument panel. At very low temperatures, a portion of the air bag door can break away from the mounting/hinge flange because of plastic embrittlement at these low temperatures and the high bending stresses encountered at this juncture.

Abstract: A trim assembly for a vehicle providing energy absorption between a structural member and a trim cover has a curved cover including a curved inner surface supporting an energy absorbing tube having a first side portion thereon that has an undeformed position and a deformed position that is permanently plasticly deformed upon the cover initially being impacted and the energy absorbing tube has a first segment thereon with an undeformed curvature substantially fully engaged with the curved inner surface of the cover and further having a second side portion overlying the curved segment to form a leaf spring action therebetween that will absorb energy by elastic deformation upon plastic deformation of the first side portion as the cover is impacted.

Abstract: A solvent flush reaction injection molding mixhead has a mixing chamber with a solvent inlet port in one end and a chemical outlet port in an opposite end. A pair of hydraulically operated chemical injectors are connected to the mixing chamber between the solvent inlet port and chemical outlet port to inject liquid reaction molding chemicals at high pressure through injector ports into the mixing chamber. The mixed chemicals are delivered through the chemical outlet port to a spray wand on the mixhead for application to a mold surface or an object requiring a foam coating.

Abstract: An air bag door arrangement is incorporated in an instrument panel that has a substrate and an uninterrupted covering for the substrate. The substrate includes an air bag opening that is closed by a door. The door has a hinged end that is clamped to the substrate by a frame that is beneath the substrate, a reinforcement bar that is above the substrate and a plurality of fasteners that force the frame and reinforcement bar toward each other. An air bag canister is attached to the frame beneath the air bag opening of the substrate and the frame is attached to automotive body structure so that the substrate is isolated from the reaction forces of the canister when an air bag housed in the canister inflates and pushes the door through the instrument panel covering.

Abstract: A metallizing apparatus for vacuum-metallizing both recessed and non-recessed surfaces of relatively massive articles such as automotive wheels includes a vacuum chamber and a linear array of electron beam-type metal particle emitters. The emitter array is positioned in the chamber to thermally evaporate metal onto each article. A rack is supported within the chamber and rotates about a horizontal rack axis between two vertical end braces. Two or more identical articles are supported to rotate on the rack about respective second and third axes as the rack rotates about the horizontal rack axis. The articles both rotate around the rack axis and each simultaneously rotate around their respective second and third rotational axes while being held in the path of metal particles emanating from the emitters. The articles are mounted on the rack so that their respective second and third rotational axes are positioned at an angle to the rack axis. Adjustable pivot mechanisms allow an operator to vary these angles.

Abstract: A method for fabricating plastic interior trim components having an insert with openings therein joined to a composite member including a shell and a foam layer, the method including die punching a hole through the shell and foam layer and die punching an edge extension on the shell to a predetermined parametric form; providing a press that is operable to compress a part therebetween and including a first platen and a second platen moveable between opened and closed positions with respect to one another; providing an insert having an opening; supporting the insert on one of said first and second platens and applying adhesive on a surface of the insert; loading the composite member on the other of said first and second platens so that the foam layer thereof is facing the adhesive sprayed insert inboard of the die cut edge extension; closing the press to compress the adhesive sprayed surface against the foam layer of the composite member for adhering the insert only to the foam layer without leakage of foam thr

Abstract: An air filter having a filter element, a support, and a seal. The support is a substantially flat and flexible screen to allow air to pass through the support. The seal is connected to a perimeter of the support and across a middle section of the support to form two sections. The filter element is attached to the support at only one of the sections.

Abstract: An instrument panel assembly includes an instrument panel carrier, a top panel and a front of dash panel of one-piece molded plastic construction. The top panel includes an upper housing part and the front of dash panel includes a lower housing part that cooperatively form a housing for components of a heating, ventilating and air conditioning system when the top and front close-out panels are attached to the instrument panel carrier. Each panel also cooperates with the instrument panel to form an air distribution duct for the heating, ventilating and air conditioning system that communicates with the housing formed by the two panels.

Abstract: A method of manufacturing a direct drive servovalve including the steps of providing a completely packaged drive motor and a hydraulic stage positioning the drive motor upon the hydraulic stage and in engagement with a valve contained within the hydraulic stage applying a signal to the motor which is proportional to a desired output signal from the hydraulic stage moving the motor while measuring the output from the hydraulic stage and when the predetermined desired output is obtained from the hydraulic stage, then securing the motor to the hydraulic stage.

Abstract: Disclosed is a direct drive servovalve having a molded plastic housing. A metal sleeve having a spool valve slidably disposed therein is placed within opposed cavities formed within opposite housing halves. The housing halves are brought together under pressure and an ultrasonic horn is activated. Energy directing beads formed on the housing halves as well as interfering surfaces about the periphery melt under a pressure and ultrasonic energy allowing the two housing halves to move toward each other and mate. Upon deactivation of the ultrasonic horn, the molten plastic material cools and forms a seal about flow ports in the metallic sleeve as well as a fusion bond about the periphery of the housing.

Abstract: A door cover assembly for concealing a supplemental inflatable restraint (SIR) system of an automotive interior trim component includes a substrate having a door section in which formed depressions are provided to strengthen the door. The depressed regions are filled with a secondary foam insert to level the outer surface of the substrate. A primary foam layer overlies the substrate and is covered by an outer vinyl shell. The leveling of the substrate by the secondary foam insert eliminates "show through" of the depressed regions on the outer Class A surface of the vinyl shell.