Abstract: A process and related assembly for creating an extrusion molded article with a chemically applied outer film. An extruded base material is formed during a first extrusion operation, following which a multi-layer film is bonded to the base material while the base material still at an above ambient temperature. The multi-layer film further includes successive layers of each of a polypropylene (PP), an adhesive, a polyethylene terephthalate (PET), a coating and s subsequent surface PET. The step of bonding of the film further occurs during an intermediate step between the first extrusion operation for forming the base material according to a given profile section and a subsequent extrusion operation for applying additional material along an edge of the film, the additional material including profile wings as required for a given design.

Abstract: A method and assembly for forming a multi-shot panel for a vehicle including the steps of providing a mold and forming therein a main body of the panel from a first rigid material, the step of forming the main body further including forming a multi-sided recess. The rigid material is transferred to a second reconfiguration of the mold for forming thereupon at least one second softer material. The panel is then transferred to a third reconfiguration of the mold for forming the heat deflecting shield. Alternative, a two shot injection molded panel can be removed from the mold and a previously formed heat deflecting shield can be attached along edges of the main body defining the multi-sided recess. In either variant, locking features are designed into the interface geometry between the heat deflecting shield and rigid main body.

Abstract: A ventilation module for a vehicle having a housing including a flap hingedly secured along an inner edge to the housing to extend across its open interior. The flap includes side edges and an interconnecting outer edge which contact, in a closed flap condition, support locations configured along the housing to define its open interior. One or more fingers extend from at least one of the side and outer edges of the flap so that the fingers abut standoff locations of the housing located in proximity to the support locations. Upon a sufficient positive air pressure condition created within the passenger compartment which overcomes a holding force exerted by the fingers against said stand-offs, the flap is allowed to open in a controlled fashion to vent to the exterior the excess air pressure, until reclosing upon achieving an air equilibrium condition.

Abstract: A fastener assembly including a hollow and structurally collapsible stem over an intermediate extending range, a solid end most extending portion being structurally rigid. A receiving portion is constructed of a deformable material having a surface, within which is configured an inner rim defined edge of a deformable material. The inner rim edge can include either of a flat profile or a chamfered shape with a narrowed profile, a diameter of an aperture bounded by the chamfered edge being less than a diameter of the solid end portion so that, upon insertion and passage of the solid portion through the narrowed rim profile, initial deformation of the chamfered rim edge shape preceding alignment of the interiorly hollowed portion, which is subsequently caused to exhibit a controlled collapse by the rim edge in order to secure the stem within the receiving portion.

Abstract: A process and assembly for incorporating a molded automotive fluid dispensing and manifold distribution system into an injection molded panel, including the steps of providing a mold and forming in a first injection molded shot a thermoplastic panel of a first material, opening the mold and positioning against a surface of the panel a previously produced manifold distribution system including at least a main manifold section and at least one branching section communicating with a nozzle outlet and reclosing the mold and subsequently forming in a second injection molded shot a second softer thermoplastic material in order to bond the manifold system to the first show panel. Other steps include forming the manifold distribution system in a secondary cavity with the first shot panel, following which a pick-and-place robot aligns the panel and manifold prior to the shot of softer material.

Abstract: A method for producing a thermoplastic panel, including the steps of providing a rotary injection tool exhibiting a die cavity and featuring at least one lifter component within the cavity. The tool is positioned to orient the cavity in a first configuration during which a first shot injection molding of a doghouse is conducted onto a receiving location of the lifter component. The cavity is open and the tool rotated to reposition the cavity in a second configuration, following which a second shot injection molding operation is conducted for forming a skin of the panel in communication with the first shot doghouse clip. Following this, the mold is opened and the finished part removed.

Abstract: A method for producing and installing a fastener, including the steps of forming an engaging portion having a projecting stem which is interiorly hollowed over at least an intermediate extending range, the stem including a solid end most extending portion, and forming a receiving portion having a surface, within which is configured an inner rim defined edge, a diameter of an aperture between said rim edge being less than a diameter of the stem. Additional steps include pressing the solid end most extending portion of the engaging portion through the inner rim edge of the receiving portion and aligning with the inner rim edge a location of the interiorly hollowed portion of the stem, causing inward collapsing of the aligned location by the rim edge to secure the engaging portion to the receiving portion.

Abstract: A closure assembly incorporating a crush barb which is molded into a recess cavity defining surface of a first piece. The crush barb is engaged by an inserting portion projecting from a second piece, the inserting portion being subsequently actuated into a collapsing and retention forming undercut with the crush barb in order to secure the pieces together. A variety of closure assemblies are provided with variations of inserting portions associated with the second piece, such including the use of an action/installation inducing tool for creating an undercut within the crush barb. Alternatively, the inserting portion may be configured with an over-center pivoting hinge which, upon being actuated, creates the crush barb undercut in order to engage the pieces together.

Abstract: A ventilation module for a vehicle having a housing including a flap hingedly secured along an inner edge to the housing to extend across its open interior. The flap includes side edges and an interconnecting outer edge which contact, in a closed flap condition, support locations configured along the housing to define its open interior. One or more fingers extend from at least one of the side and outer edges of the flap so that the fingers abut standoff locations of the housing located in proximity to the support locations. Upon a sufficient positive air pressure condition created within the passenger compartment which overcomes a holding force exerted by the fingers against said stand-offs, the flap is allowed to open in a controlled fashion to vent to the exterior the excess air pressure, until reclosing upon achieving an air equilibrium condition.

Abstract: A method for producing a thermoplastic panel, including the steps of providing a rotary injection tool exhibiting a die cavity and featuring at least one lifter component within the cavity. The tool is positioned to orient the cavity in a first configuration during which a first shot injection molding of a doghouse is conducted onto a receiving location of the lifter component. The cavity is open and the tool rotated to reposition the cavity in a second configuration, following which a second shot injection molding operation is conducted for forming a skin of the panel in communication with the first shot doghouse clip. Following this, the mold is opened and the finished part removed.

Abstract: A fastener assembly including a hollow and structurally collapsible stem over an intermediate extending range, a solid end most extending portion being structurally rigid. A receiving portion is constructed of a deformable material having a surface, within which is configured an inner rim defined edge of a deformable material. The inner rim edge can include either of a flat profile or a chamfered shape with a narrowed profile, a diameter of an aperture bounded by the chamfered edge being less than a diameter of the solid end portion so that, upon insertion and passage of the solid portion through the narrowed rim profile, initial deformation of the chamfered rim edge shape preceding alignment of the interiorly hollowed portion, which is subsequently caused to exhibit a controlled collapse by the rim edge in order to secure the stem within the receiving portion.

Abstract: A mold assembly for forming a component exhibiting a sealed interior, including providing first and second mold halves, forming first and second half shells of material within cavities defined within each of the mold halves, and upon mating the mold halves together in a first closed mold configuration. The mold halves are reopened, with at least one of the shells being subsequently reoriented such that the first and second half shells are arrayed in opposing fashion with perimeter extending edges of each half shell arranged in contact with one another. Additional steps include reclosing the mold halves and subsequently forming a second perimeter extending material in contact with the contacting perimeter extending edges in order to bond the half shells together, upon which the mold halves are reopened and a completed component removed.

Abstract: A method for forming a component exhibiting a sealed interior, including providing first and second mold halves, foaming first and second half shells of material within cavities defined within each of the mold halves, and upon mating the mold halves together in a first closed mold configuration. The mold halves are reopened, with at least one of the shells being subsequently reoriented such that the first and second half shells are arrayed in opposing fashion with perimeter extending edges of each half shell arranged in contact with one another. Additional steps include reclosing the mold halves and subsequently forming a second perimeter extending material in contact with the contacting perimeter extending edges in order to bond the half shells together, upon which the mold halves are reopened and a completed component removed.

Abstract: A method and assembly for reshaping an elongated plasticized article including a pair of first and second spaced apart fixtures adapted to supporting extending ends of an elongated article. The fixtures each exhibit a contoured upper surface upon which the elongated article is adapted to being supported in adhering fashion. A heated airflow is delivered in communication with at least one surface of the article and, upon cooling, the article exhibits an extending profile matching the contoured upper surface. A pre-heat station pre-softens at least an extending subset portion of the article prior to transfer to the fixture. Pluralities of gripping fingers communicate with an underside of the contoured upper surface and are adapted to engage at least underside accessible cross sectional profile locations of the article.

Abstract: An assembly for reshaping an elongated plasticized article includes a heated fixture upon which the elongated article is supported in adhering fashion to a contoured upper surface. Following heating, the article is transferred to a cooling fixture exhibiting a further contoured upper surface and, upon subsequent cooling, the article exhibits a final multi-dimensional extending profile matching the contoured upper surface of the cooling fixture. A further variation of the assembly includes an elongated and bowed track supporting a fixed jig at an end thereof. A slidable jig is traversable along the track and actuated by a ram in directions towards and away from the first jig.

Abstract: An assembly and process for forming a two stage extruded pipe having a central inner sleeve and a pair of outer attached lobes. The central sleeve shaped (also termed a grout receiving tube) is produced in an initial extrusion operation, following which it enters a cross head operation where a pair of outer lobes are attached to cross sectional exterior surface locations according to a second stage extrusion operation so as to be integrally formed therewith. Other steps include cooling of the dual stage extruded pipe, as well as sectioning and stacking the pipe. Additional steps include forming elongated slots or apertures into the central sleeve portion of the finished extrusion, such in non-interfering fashion with the individual passageway defining and lobes.

Abstract: An assembly and process for forming a two stage extrusion of an elongated marine dock from a plasticized material, such as including but act limited to extruding a first generally “L” shaped bracket from a first more rigid thermoplastic, following which a cross head die arrangement is utilized in order to extrude a secondary arcuate and flexible material in extending fashion from a lower side of the “L” bracket. The secondary/flexible elastomer is extracted in an open flexed position relative to the first extruded bracket, and further such that, following completion, can be flexed into a closed engagement with an upper perpendicularly extending side of the bracket.

Abstract: A process and assembly for producing a two stage injection molded article encapsulating an oriented glass strand mat substrate. A rotary press is incorporated into the injection mold assembly and which enables repetitive repositioning of an intermediate injection molded article into a second mold defining cavity for second stage molding and simultaneous with first stage molding of a subsequent glass strand composite positioned within the first mold cavity.

Abstract: A retaining feature incorporated into a mounting surface of a plasticized article which is adapted to receive and retain a fastener prior to final assembly. The retaining feature exhibits an irregular and three dimensional shaped closed profile defined along an interior perimeter configured within the mounting surface and which establishes a degree of flex or bend upon insertion of the fastener with minimal loss of material. The insertion force can be any of lesser, equal to or greater than the extraction force, in combination with providing a rated side load breaking/shearing strength of the bolt from the material defined retaining feature.