Abstract: An article including a substrate having a first surface, an opposing second surface and a peripheral edge defined between the first surface and the second surface. A shaped foam body made of a polymeric material is attached to the substrate. In the space between the peripheral edge of the substrate and a peripheral edge of the shaped foam body, there is a margin that is substantially free of any polymeric material of the shaped foam body, and a border area that includes an exposed extension of the polymeric material of the shaped foam body having a substantially predetermined shape and size. A tool and process for making the above is described as well.

Abstract: An integrated air bag chute structure that provides sealing of an air bag aperture in an instrument panel substrate during a foam-in-place process. The structure provides an extended flange with flexible tapered edges that surround the aperture. The tapered edges are compressed against the upper surface of the substrate to seal and surround the substrate aperture when the chute structure is inserted into and retained in the substrate aperture. The air bag chute structure further defines a door support panel with pre-weakened molded edges and a hinge which are all integrally connected to the structure and flange without gaps that would allow for leakage during the foam-in-place process.

Abstract: An attachment clip includes an inner body portion and an outer body portion separated by a cavity, and a secondary spreader located between the cavity and a bottom of an elongated cavity. The secondary spreader is located along an axis passing through the cavity and the elongated cavity to increase the flexibility of the inner and outer body portions. The attachment clip is integrally formed of the same material with a substrate by using an injection molding process, or other similar process, thereby eliminating the need for additional fasteners to attach the attachment clip to the substrate.

Abstract: A vehicle door handle assembly has a support that includes a concave shell having a pair of vertically spaced bosses with pivot holes for two concentric shafts. One shaft is operated by a handle in the shell and moves an operating lever behind the shell. The other shaft is operated by a lock knob in the shell and moves a second operating lever behind the shell.