Abstract: A motor vehicle is provided with an air bag system having a singular air bag that deploys downward from the ceiling to cushion the front and both sides of both the driver and a front seat passenger from over their head and to at least their shoulders to prevent their impacting with upper interior portions of the vehicle and with each other in a collision. The air bag includes an elongated front section that extends transverse of the vehicle along the front of the seats, elongated side sections that extend rearwardly from the front section along the outer side of the respective seats, and an elongated intermediate section that extends rearwardly from the front section between the seats.

Abstract: A process for manufacturing a metallized part comprises the following steps. A part is provided made from a substrate material selected from the group consisting of thermoplastic urethane (TPU), TPU alloys, polyester alloys, nylon, thermoplastic olefins (TPO) and aluminum. A single protective layer (combined primer/basecoat) is spray deposited, flashed and cured over the substrate. Over the combined primer/basecoat layer, a layer of corrosion prone metal is vacuum deposited to form a discontinuous film covering the combined primer/basecoat layer. A layer of clear resinous protective dielectric topcoat is spray deposited and cured to completely cover the layer of vacuum deposited corrosion prone metal material and fill channels formed in the discontinuous film layer.

Abstract: A cover for an air bag unit having a patterned tear seam therein defined by an integrally bonded, thermoplastic filler strip as the cover material and including a material having properties different than that of 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 an opening therein that has the tear seam pattern. The opening is later filled with the lesser strength thermoplastic material to form an integrally bonded thermoplastic filler strip.

Abstract: A process for manufacturing a metallized part using the island coating method, including spray depositing a primer layer, basecoat layer, or combined primer/basecoat layer. Each layer contains an increased amount of film forming polymer by using liquid CO.sub.2 as a supplemental carrier along with a reduced amount of organic solvent carrier thereby reducing waste disposal costs and environmental concerns. Further, this modified island coating system can be used to deposit layers of 1.5 to 2.0 mils thick and maintain the aesthetic properties of the metallizing island coating system at a reduced cost and with minimal variability among parts.

Abstract: A driver assembly for driving fasteners into a workpiece comprises a multilobular fastener engaging portion for engagement in a complementary multilobular socket or recess on a fastener. Each lobe is bounded on opposite sides by a flute, and each lobe includes a driving side wall and a trailing tapered side wall. The driving side walls are adapted to contact the complementary lobular portions of the fastener for applying torque to the fastener, while the trailing tapered side wall is aligned to contact the complementary lobular portion in wedged engagement at a point when the fastener is applied to the fastener portion. A fastener socket is also provided having a driven side wall and a trailing tapered side wall, which is constructed substantially similarly to the tapered side wall of the drive bit and which provides similar attributes.

Abstract: An improved helicopter landing gear assembly to substantially increase useful service life. The crosstubes are constructed of a material that allows use of thicker crosstubes thereby reducing the operating stress in the crosstubes and helping to increase the fatigue life, while at the same time preserving the required energy absorption characteristics. The inside and outside of the crosstubes are shot peened to help increase the fatigue life. The crosstubes are formed in an unstable temper condition thereby reducing the stress that is induced into the part during formation, and thus helping to increase the fatigue life. The straps are connected to the crosstubes by fasteners located at the sides of the straps and closer to the neutral bending axis of the crosstube so that the fasteners and the fastener holes are subjected to lower stress levels. The combination of these improvements results in a substantially increased life of the landing gear assembly.

Abstract: A steering wheel (12) incorporates an air bag unit (22). The air bag unit has a cover door (30) with a transducer (38) molded in a deformable front wall (35) of the cover door. The transducer can be a force sensitive resistor (38) which is operably connected to an electrical circuit (42) that actuates a horn (44) when the circuit senses a change in the resistance of force sensitive resistor (38). The force sensitive resistor (38) produces a suitable change in resistance when hand pressure is exerted on the front wall (35).

Abstract: An automobile door having an interior trim panel with air flow control openings at a bottom edge thereof. The air flow control openings direct outside air entering the normal drain holes in the door onto the floor of the passenger compartment to thereby prevent this air from entering the passenger compartment through partially sealed openings in the trim panel in which a door release handle and power door and power window switches are received.

Abstract: A method of forming a pultruded shaped composite material comprising carbon fiber having a diameter not greater than 0.001 inch aligned linearly with a degree of waviness defined by an average amplitude to length (A/L) ratio of less than 0.9 percent in a matrix is formed around the fiber and solidified or cured into a rigid form that will not melt during subsequent processing steps to prevent an increase in waviness during subsequent processing steps. The compressive strength of the composite material approaches the tensile strength of the material. The matrix material consists essentially of a resin present in the range of about 10 to 50 percent by volume of the composite material. The A/L ratio is determined by measuring the distribution of angularity found in the aligned carbon fibers in a selective cross section cut at five degrees to the fiber plane, wherein the standard deviation for a 300 sample angularity measurement is not greater than 0.88 degrees.

Abstract: There is disclosed herein a molded plastic front bumper beam for a vehicle. The bumper beam includes upper and lower separate hollow compartments for carrying selected fluids. The upper and lower compartments are interconnected by an integral front wall segment. Dual openings are formed in the rear portion of each compartment adapted to accommodate receiving and dispensing fluids, such as radiator coolant, windshield washer fluid, rear window washer fluid, and/or head lamp washer fluid.

Abstract: An air bag cover door assembly utilizes a releasable fastener along each side of the air bag cover door to provide a predetermined opening characteristic for the cover door. The fasteners can be hook and loop tape, mechanical interlocks, adhesive strips, etc., with one half of each fastener secured to the inside surface of the cover door and the other half secured to a substructure, such as a dashboard pad retainer, in mating engagement with the first half. The fasteners are located along the sides of the cover door proximate the hinging axis of the cover door so that expansion of the air bag causes the cover door to initially hinge along a line extending between the engaged fasteners and then causes the fasteners to separate, allowing the cover door to swing open fully about its hinging axis.

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: An air bag restraint system is housed within an interior trim product with a hidden door that is opened when an air bag is inflated for deployment into the passenger car or a vehicle. The door is formed in a reinforced segment of a layer of low density rigid foam material that forms the load bearing support for the interior trim product and a backing for an outer skin or decorative surface that forms the outer cover of the interior trim product. The hidden door is formed by cast in place segments in the reinforced segment of the layer of low density rigid foam material a door hinge segment and a weakened tear seam segment which separates when the air bag impacts thereagainst to tear the outer skin for forming an opening therethrough for deployment of the air bag into the passenger compartment of a vehicle.

Abstract: A nozzle assembly (16), for spraying a liquid such as a urethane prepolymer on a substrate, has a liquid spray nozzle (28) with a center line (56). Air nozzles (30), with center lines (62) that are substantially parallel to the center line (56) of the liquid spray nozzle (28), are provided in the nozzle assembly (16) around the liquid spray nozzle. Air passing from the air nozzles (30) surrounds and encloses the liquid spray and decreases the size of the liquid spray fan pattern (58 or 70). The air spray nozzles (30) can be positioned in the nozzle assembly (16) to change the shape of the liquid spray fan pattern (58 or 70) as well as the size. Mixing of air and liquid is minimized by spraying air and liquid in parallel paths.

Abstract: A closure for an air bag assembly includes a flexible outer skin and a layer of foam material covering a retainer member having an air bag deployment opening therein closed by a moveable door that is overlapped with the retainer member to support the door against movement inwardly of the retainer member while providing free hinging movement thereof with respect to the retainer member for stressing and separating the layer of foam and the outer skin for forming a deployment path therethrough for the air bag.

Abstract: A dual-purpose bulkhead structure functions to support normal aircraft operational loads and to absorb energy in a controlled manner during a crash. An integral fuel tank comprises a fuel compartment and a crashworthy flexible fuel cell. The fuel compartment includes two dual-purpose bulkheads and crushable foam disposed between the sides of the fuel cell and the bulkheads and sides of the fuel compartment. The foam limits fuel pressure loads on fuel compartment bulkheads and sides during a crash, thereby preventing their failure.

Abstract: An interior trim product and supplemental inflatable restraint assembly includes a canister for generating gas to inflate an air bag for deployment into the passenger compartment of a motor vehicle. Access to such assemblies is closed by a door that is held down by a cable release mechanism that will separate from the door as the door is opened during supplemental inflatable restrain deployment.

Abstract: The mold (10) for forming an article includes a first mold member (16) with a first mold surface (24) and a second mold member (18) with a second mold surface (26). When the mold (10) is closed, the first and second mold surfaces (24) and (26) form a mold cavity (28). Lances (58) are forced into the mold cavity (28) by linear actuators (60) to pierce an article (12) and then withdrawn from the mold chamber. Each Lance (58) allows gas under pressure to escape from the article (12) through the clearance between the lance and the bore (56) in which the lance is mounted. Relieving gas pressure in the article (12) allows the mold (10) to be opened without distortion of the article and shortens mold cycle time.

Abstract: An instrument panel has an integral door cover for concealing a supplemental inflatable restraint system in a vehicle passenger compartment. The door cover includes a flap that is an integral part of a flexible plastic skin of the instrument panel. The plastic skin is cast in a special mold with a raised apexed rib that forms grooves outlining the flap that have a thin tear seam at their bottom.