Patents by Inventor Bruce Batchelder
Bruce Batchelder has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 6533312Abstract: An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in2 to 35 in2, and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.Type: GrantFiled: April 18, 2000Date of Patent: March 18, 2003Assignee: Textron Automotive Company, Inc.Inventors: Craig B. Labrie, Bruce A. Batchelder, John D. Gray, Marie J. Hersman
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Publication number: 20020153710Abstract: An airbag door system is provided comprising a substrate, an outer shell and a foam where all three layers possess a line of mechanical weakness with each line of mechanical weakness at least partially separating each layer into an airbag door portion and a trim member portion. The substrate line of mechanical weakness comprises at least one substrate aperture. The outer shell line of mechanical weakness comprises an outer shell reduced thickness portion defined by an outer shell sever extending partially through an outer shell thickness from an outer shell lower surface towards an outer shell upper surface. The foam line of mechanical weakness comprises a foam reduced thickness portion defined by a foam sever extending partially through a foam thickness from a foam lower surface towards a foam upper surface. The outer shell line of mechanical weakness is displaced relative to a foam line of mechanical weakness.Type: ApplicationFiled: March 7, 2002Publication date: October 24, 2002Inventors: John D. Gray, Philip A. Bunn, Bas Korte, Chris Hayes, Bruce Batchelder
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Patent number: 6457738Abstract: An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in2 to 35 in2, and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag having a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.Type: GrantFiled: March 19, 2001Date of Patent: October 1, 2002Assignee: Textron Automotive Company, Inc.Inventors: Craig B. Labrie, Bruce A. Batchelder, John D. Gray, Marie J. Hersman
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Publication number: 20020074776Abstract: An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in2 to 35 in2, and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag having a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.Type: ApplicationFiled: March 19, 2001Publication date: June 20, 2002Inventors: Craig B. Labrie, Bruce A. Batchelder, John D. Gray, Marie J. Hersman
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Patent number: 6280666Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.Type: GrantFiled: April 16, 1999Date of Patent: August 28, 2001Assignee: Textron Automotive CompanyInventors: Michael J. Gallagher, Bruce A. Batchelder
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Publication number: 20010008315Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.Type: ApplicationFiled: February 19, 2001Publication date: July 19, 2001Applicant: Textron Automotive Company, Inc,Inventors: Michael J. Gallagher, Bruce A. Batchelder
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Patent number: 6203056Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a door perimeter including a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates, it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.Type: GrantFiled: June 16, 1999Date of Patent: March 20, 2001Assignee: Textron Automotive Company Inc.Inventors: Craig B. Labrie, Edwin V. Stawicki, Nelson J. Morren, Jack J. Kennedy, Vernon A. Daniels, Jimmy C. Rogers, John D. Gray, Bruce A. Batchelder, Michael J. Gallagher, Richard D. Rhodes, Jr.
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Patent number: 6131945Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.Type: GrantFiled: June 29, 1999Date of Patent: October 17, 2000Assignee: Textron Automotive Company Inc.Inventors: Craig B. Labrie, Jimmy C. Rogers, John D. Gray, Bruce A. Batchelder, Michael J. Gallagher, Richard D. Rhodes, Jr.
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Patent number: 5952630Abstract: A vehicle interior trim panel electrical switch assembly (10) includes a switch panel portion (16) with a continuous outer surface (18). Force sensitive resistor switches (20a-20g) are supported on the switch panel portion (16) and are secured to the inner surface of a skin cover having a continuous outer surface (18) and forming the outer layer of a soft feel composite. The force sensitive resistor switches are embedded in the soft feel composite either as being cast in a layer of flexible foam or being applied within preformed openings in a layer of flexible foam in certain embodiments in which case they are associated with a circuit module (34) that negates preloading effects due to thermal expansion caused by changes in ambient conditions. In a preferred embodiment the correction occurs due to a circuit configuration that corrects for such preloading effects on a deflection rate basis. The circuit module (34) for each switch (20a-20g) may also include a relay in high power applications.Type: GrantFiled: July 24, 1998Date of Patent: September 14, 1999Assignee: Textron Automotive Company Inc.Inventors: Scott M. Filion, Bruce A. Batchelder
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Patent number: 5941558Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.Type: GrantFiled: October 14, 1997Date of Patent: August 24, 1999Assignee: Textron Automotive Company Inc.Inventors: Craig B. Labrie, Jimmy C. Rogers, John D. Gray, Bruce A. Batchelder, Michael J. Gallagher, Richard D. Rhodes, Jr.
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Patent number: 5922256Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.Type: GrantFiled: June 26, 1997Date of Patent: July 13, 1999Assignee: Textron Automotive Company, Inc.Inventors: Michael J. Gallagher, Bruce A. Batchelder
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Patent number: 5560646Abstract: 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.Type: GrantFiled: April 24, 1995Date of Patent: October 1, 1996Assignee: Davidson TextronInventors: John Gray, Bruce Batchelder, Jim Rogers, Robert Booth
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Patent number: 5093066Abstract: A method for molding a thin walled plastic shell utilizes the following apparatus. An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).Type: GrantFiled: November 2, 1990Date of Patent: March 3, 1992Assignee: Davidson Textron Inc.Inventors: Bruce A. Batchelder, John D. Gray
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Patent number: 5072967Abstract: A cover assembly for an airbag restraint has a smooth cover and a load bearing insert for concealing an airbag restraint system having a housing, an airbag and a gas generator which includes an inflatant for inflating the airbag for deploying the airbag through the smooth outer cover member. The outer cover member has weakened sections on the inboard surface and filler material is disposed against the cover member to prevent inward collapse of the outer cover member at the weakened sections. An insert is formed in situ of the filler material in an opening in a restraint member and the insert is engaged during initial inflation of the airbag to displace the filler material so as to stress the outer cover member at the weakened sections thereof for separating a hidden door segment from the cover member as the airbag is inflated and solely in response to such inflation prior to deployment of the airbag into the passenger compartment.Type: GrantFiled: July 12, 1990Date of Patent: December 17, 1991Assignee: Davidson Textron Inc.Inventors: Bruce Batchelder, Scott Rafferty
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Patent number: 5061428Abstract: A method for forming a plastic coating for a foam molding insert or retainer member includes the steps of preforming an insert member having openings therethrough; partially sealing the openings and/or the perimeter edge of the insert member with protuberances formed on a conforming buck; completely sealing the openings and/or the perimeter edge by spraying polymeric material against the insert and the protuberances only in the vicinity of the hole and the perimeter edge to form seals without covering the insert with a film wrap; curing the seals to provide a leak proof patch which prevents foam leakage through the insert during a foam molding process.Type: GrantFiled: January 4, 1990Date of Patent: October 29, 1991Assignee: Davidson Textron Inc.Inventor: Bruce A. Batchelder
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Patent number: 5046758Abstract: A cover assembly for an air cushion restraint has a smooth cover with a layer of foam connected between the cover and a load bearing insert for covering a housing for an airbag and a gas generator which generates an inflatant for the airbag for deploying the airbag; three cutters are pivotally connected to the insert member to cut an insert cover member from the insert and to pierce the smooth outer cover member during inflation of the airbag so as to form a self-piercing cover assembly which will be cut to form a three sided opening through the cover assembly through which the airbag is deployed; the cutters are actuated by an insert cover member support system which will operate the cutters as the airbag is inflated to cause cutting edges on the cutters to pierce the smooth outer cover member. The cutters are recessed within the cover assembly to avoid incidental contact with the cutting edges prior to deployment.Type: GrantFiled: November 13, 1990Date of Patent: September 10, 1991Assignee: Davidson Textron Inc.Inventors: Scott Rafferty, Bruce Batchelder, Mark Dupuis
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Patent number: 5046941Abstract: An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).Type: GrantFiled: October 13, 1989Date of Patent: September 10, 1991Assignee: Davidson Textron Inc.Inventors: Bruce A. Batchelder, John D. Gray
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Patent number: 4860815Abstract: A method and apparatus for manufacturing a composite article by use of a mold core and a cavity block and wherein a skin and insert are placed in the mold cavity and foam precursors are poured into the mold cavity to complete the article includes a process in which a series of part replicas are formed and used to cast thermally stable liners that are carried by the mold core and mold cavity. The thermally stable liners have low melt temperatures and can be reused and recast following wear during the molding process. The liners are made from material which has low shrinkage and expansion rates to define a mold assembly that will produce repeatable parts.Type: GrantFiled: August 17, 1987Date of Patent: August 29, 1989Assignee: Davidson Textron Inc.Inventors: Kent Parker, Bruce Batchelder, Norman Clavette