Abstract: A plastic shopping cart is disclosed. In accordance with certain aspects of the present invention, all of the components of a shopping cart are formed from a moldable material such as, for example, a thermoplastic resin by means of an injection molding process or the like. The shopping cart is configured so that any metallic parts that are used to connect the various plastic components together are shielded from the ambient environment. This virtually eliminates any rusting and corrosion of any metallic parts that are used to connect the various components of the shopping cart together.

Abstract: A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A foil-covered automotive interior plastic part including a decorative preform is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a outer surface of a plastic structural substrate at foil-receiving portions of the outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the foil-receiving portions and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but only the side surfaces of the raised design portions which extend above a front surface of the preform. Preferably, the raised design portions represent screw heads.

Abstract: An automotive air bag cover is provided having a decorative applique preform bonded thereto completely about a pair of flap portions of a front panel of the cover. The air bag cover is manufactured from plastic and the front panel is adapted to enclose an uninflated automotive air bag. The front panel includes inner and outer surfaces. Side panels are further provided and are connected to and extend rearwardly from the front panel. The decorative applique preform is bonded to the entire outer surface of the front panel except for the flap portions. Seams are provided for permitting the air bag to inflate and exit the front panel. The decorative applique preform is bonded to the front panel adjacent the seams in a non-overlapping fashion such that the decorative applique preform does not interfere with exit or inflation of the air bag.

Abstract: A foil-covered plastic part is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a plastic outer surface of a decorative preform at foil-receiving portions of the plastic outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the at least one foil-receiving portion and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but not the side surfaces of the raised design portions. Preferably, the raised design portions represent graphical information.

Abstract: A method and system of manufacturing an air bag cover assembly utilizing infrared radiation is disclosed. The assembly includes a front panel, a back plate, a switch and infrared-absorbing material. Initially, the front panel and the back plate are positioned so that inner surfaces of the front panel and the back plate define a switch pocket therebetween. Then the switch is positioned in the switch pocket. Thereafter, infrared radiation is directed at the infrared-absorbing material for a time sufficient to heat the infrared-absorbing material to a desired temperature. The amount of heat applied to the infrared-absorbing material by the infrared radiation is controlled by a controller. Finally, the heated material cools to fixedly secures the back plate to the front panel. The heated material may be forced to flow prior to cooling.

Abstract: A method is provided for manufacturing a painted plastic component having a badge, emblem or other ornamentation, such as air bag covers having a badge, or wherein the component is the badge itself. The method includes providing a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.

Abstract: A motor vehicle trim assembly includes a plastic outer trim panel having an opening, a door for closing the opening, an inner trim panel for storing an uninflated air bag curtain, a hinge for the door and a latch for holding the door in its closed position yet still allow deployment of the air bag curtain through the opening in the outer trim panel. Both the door and the hinge comprise a single injection molded part. The assembly preferably includes a lock for locking the door in its closed position yet also allow deployment of the air bag curtain. The inner trim panel, the latch and the lock all comprise a single injection molded part. The inner trim panel has a conduit portion integrally formed with a solid base wall portion which receives and retains the uninflated air bag curtain as well as an inflator of the system. A gas channel defined by the conduit portion may conduct fluids or pass solid objects such as electric wires through the inner trim panel.

Abstract: A foil-covered plastic part is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a plastic outer surface of a decorative preform at foil-receiving portions of the plastic outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the at least one foil-receiving portion and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but not the side surfaces of the raised design portions. Preferably, the raised design portions represent graphical information.

Abstract: A foil-covered plastic part is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a plastic outer surface of a decorative preform at foil-receiving portions of the plastic outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the at least one foil-receiving portion and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but not the side surfaces of the raised design portions. Preferably, the raised design portions represent graphical information.

Abstract: A snap-on thermoplastic air bag cover mountable onto an air bag container assembly includes a novel mechanism for attaching a horn backing plate to the cover. The assembly includes a container having a retaining member and a retaining bracket. The cover includes a front panel having inner and outer surfaces and is adapted to overlie an uninflated air bag contained within the container. The cover also includes a plurality of side walls connected to and extending rearwardly from the inner surface of the front panel, a horn switch lying behind the inner surface of the front panel, and a plurality of locking blocks having an extending snap-on groove and which are connected to their respective side walls. Two of the locking blocks have a groove defined in rearwardly facing surfaces thereof. The cover also includes a backing section with a back plate cooperating with the front panel to form a hollow compartment for the switch. The switch is activated by depression of the front panel at its outer surface.

Abstract: An air bag cover assembly for a motor vehicle is provided and includes a plastic substrate which is adapted to enclose an uninflated automotive air bag and a switch. The substrate has an outer surface and an inner surface. The outer surface has a recessed portion defining therebehind a switch location area. Also included is a badge which is bonded to the substrate and includes a relatively soft plastic preform which is compatible with the substrate and a foil top layer. The badge is shaped correspondingly to be received in and secured to the recessed portion of the substrate. The badge also defines a switch interface for actuating the switch by applying pressure to the badge at it front outer surface.

Abstract: A foil-covered automotive interior plastic part including a decorative preform is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a outer surface of a plastic structural substrate at foil-receiving portions of the outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the foil-receiving portions and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but only the side surfaces of the raised design portions which extend above a front surface of the preform. Preferably, the raised design portions represent screw heads.

Abstract: A molded instrument panel having a plastic front panel and incorporating an integral air bag door is disclosed wherein the air bag door is hinged to the front panel by overlapping integral plastic members to ensure that the door does not separate from the instrument panel during air bag deployment. The instrument panel also includes a plastic frame integrally formed on an inner surface of the front panel which together with the door, encloses an uninflated air bag. Preferably, the hinge and portions of the frame are formed by a pressurized fluid so as to be hollow, thereby facilitating swinging movement of the door while preventing sink marks on an outer surface of the front panel.

Abstract: An air bag cover having a decorative badge secured thereto is made by injection molding a thermoplastic elastomeric body in an injection mold having a shape defining the air bag cover. Slots are formed at predetermined spaced locations extending through the air bag cover. The decorative badge has a plurality of tabs extending therefrom at predetermined spaced locations corresponding to the spaced locations of the slots formed in the air bag cover. The tabs are inserted through the slots at a front surface of the air bag cover and bent against a rear surface of the air bag cover to create a substantially constant load on the elastomeric body. The elastomeric body exerts an opposing reaction to the constant load so as to allow the decorative badge to be secured to the air bag cover.

Abstract: A foil-covered plastic part is provided including a hot stamping foil having a foil top layer disposed on a plastic bottom layer which, in turn, is bonded to a plastic outer surface of a decorative preform at foil-receiving portions of the plastic outer surface. A hot stamping machine is operated for a time sufficient to generate a pressure and temperature sufficient to melt and combine the top surface of the at least one foil-receiving portion and the plastic bottom layer of the hot stamping foil to form the foil-covered plastic part. The at least one foil-receiving portion includes a plurality of raised design portions having top and side surfaces. The foil layer completely covers the top surfaces but not the side surfaces of the raised design portions. Preferably, the raised design portions represent graphical information.

Abstract: An automotive air bag cover is provided having a decorative applique preform bonded thereto completely about a pair of flap portions of a front panel of the cover. The air bag cover is manufactured from plastic and the front panel is adapted to enclose an uninflated automotive air bag. The front panel includes inner and outer surfaces. Side panels are further provided and are connected to and extend rearwardly from the front panel. The decorative applique preform is bonded to the entire outer surface of the front panel except for the flap portions. Seams are provided for permitting the air bag to inflate and exit the front panel. The decorative applique preform is bonded to the front panel adjacent the seams in a non-overlapping fashion such that the decorative applique preform does not interfere with exit or inflation of the air bag.

Abstract: An air bag cover assembly is provided including a front panel adapted to overlie an undeployed air bag, an ornamental pad permanently fastened to the front panel within an outer recessed portion, and a membrane-type switch lying behind the rear inner surface of the pad in a switch location area defined by a plastic top plate and an ornament of the ornamental pad. In a first embodiment, the ornament is a plastic ornament integrally formed with the plastic top plate. In a second embodiment, the ornament is fixedly secured as a separate part to the plastic top plate. In the second embodiment, the plastic top plate is a thermoplastic elastomeric body having a front surface and a rear surface.

Abstract: An air bag cover having a decorative badge secured thereto is made by injection molding a thermoplastic elastomeric body in an injection mold having a shape defining the air bag cover. Slots are formed at predetermined spaced locations extending through the air bag cover. The decorative badge has a plurality of tabs extending therefrom at predetermined spaced locations corresponding to the spaced locations of the slots formed in the air bag cover. The tabs are inserted through the slots at a front surface of the air bag cover and bent against a rear surface of the air bag cover to create a substantially constant load on the elastomeric body. The elastomeric body exerts an opposing reaction to the constant load so as to allow the decorative badge to be secured to the air bag cover.

Abstract: An air bag cover assembly includes a plastic cover section, a switch section, a backing section and a set of temporary fasteners for fastening the backing section to the cover section to maintain alignment of sets of holes formed in the cover section, the backing section and the fasteners, which aligned holes provide clearance for a set of permanent fasteners used to secure the air bag cover assembly to an air bag housing assembly. The temporary fasteners preferably take the form of a set of annular members which are integrally formed on a rearwardly extending member of the backing section and which provide a snap-in fastening of the rearwardly extending member to a side panel of the cover section. The rearwardly extending member of the backing section is attached to a back plate of the backing section in a living hinge-like fashion to facilitate deployment of an air bag.