Abstract: A cover for covering an air bag in a motor vehicle has a thin elastic plastic skin, a rigid substrate and an intermediate layer of soft plastic foam. The skin has a tear seam and the substrate includes a door that is impacted by the inflating air bag and presses outward against the foam layer and the skin to tear the foam layer and the tear seam and then swing outward with a torn section of the foam layer and skin to form an opening in the cover for deployment of the air bag into the passenger space in the vehicle. The tear seam in the skin is formed with extremely small laser machined holes that are not observable to a person of normal vision when viewed from a normal viewing distance in the passenger compartment by having a maximum hole size dimension at the outer side of the skin that does not exceed about 0.0005 inches.

Abstract: Method and apparatus including a powder box and heatable shell tool are disclosed for forming a thermoplastic automotive air bag cover skin with a lesser strength thermoplastic tear seam strip insert wherein the latter is initially formed with a protruding rib on one side and a pointed ridge on an opposite side. A heat resistant elastomeric transfer socket attached to the powder box interior receives and holds the insert rib and thereby the insert in a prescribed tear seam configuration and then positions the tear seam strip insert against a heated skin defining mold surface on the shell tool when the powder box is joined with the latter. The skin is formed by casting thermoplastic powder from the powder box against the heated mold surface and about the tear seam insert.

Abstract: A modular assembly for separating a passenger compartment from an engine compartment in an automotive vehicle body comprises three structural cross car members that combine to provide sufficient cross car stiffness between the side pillars so as to eliminate any need for an upper cross car beam at the cowl of the vehicle body. The three structural cross car members include a front of dash panel, an intermediate close out panel and an instrument panel carrier that form two rows of ducts for meeting the needs of the heating, ventilating and air conditioning system of the vehicle and the wiring requirements of the instrument panel. The instrument panel carrier is part of a covered instrument panel subassembly that includes a shell and an underlying foam cushion. The foam cushion is foamed in place in a mold that includes a slide and pivot mechanism for manipulating a mold lid and clamp between a closed clamped position and a shaping position where the molded subassembly is accessible for a shaping operation.

Abstract: A retractable speaker assembly for an automobile is disclosed which includes a housing containing at least one loudspeaker, a first actuator for selectively moving the housing between a retracted position and an extended position, and a second actuator for rotating the housing sideways so that the speaker can be directed toward the left or right side of the automobile interior.

Abstract: An apparatus and process for manufacturing multiple thin walled hollow shells for parts such as automobile door panels, arm rests, and instrument panels from thermoplastic plastisol includes a pair of plastisol charge boxes each forming a separate compartment and members for joining the charge boxes with an open ended mold. The mold has a divider rib thereon that is inaccessible by straight vertical engagement of a seal assembly on the divider. An indexable divider wall is operatively connected between the charge boxes so that the divider wall can be selectively extended and retracted at an angle with respect to the vertical and against the mold at the divider rib thereon for allowing separation of the casting surfaces having different colors fixed thereon and the subsequent fusing of the casting surfaces to one another at the divider.

Abstract: 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).

Abstract: A method for manufacturing decorative features in situ in a base layer of cast plastic material includes the steps of providing a heated mold tool with a selectively heated surface in the form of a desired decorative feature; depositing a covering of thermoplastic material in the recessed surface and heating the recessed surface to partially fuse the thermoplastic material on the recessed surface to form segments of plastic corresponding to the desired decorative feature; dumping excess thermoplastic material from the heated mold tool; thereafter spray coating the mold at the recessed surface to stabilize the location of the partially fused material in the recessed surface; reheating the mold tool to partially remelt the retained stabilized segments and thereafter depositing a base layer of thermoplastic material across the full surface of the mold and reheating the mold to bond the retained stabilized segments to the base layer and cooling and stripping the mold to form a finished plastic shell having a deco

Abstract: 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).

Abstract: Apparatus for manufacturing thin-walled hollow shells for parts such as automobile door panels, control and instrument panels and the like includes a charge box or powder box for supplying dry thermoplastic material to separate casting surfaces on a heated mold selectively connected to the charge box during a casting process. A selectively pressurizable inflatable seal gasket is connected to the charge box for sealing a division surface on the heated mold which surface separates the casting surfaces of the mold. The inflatable seal gasket includes a base portion fixed to the charge box; an inflatable core with expandable walls to bridge the distance between the charge box and the division surface and a seal bead that sealingly engages the division surface when the seal gasket is inflated to keep the division surface clean for a subsequent application of material to form a connector bond between previously cast two tone colored segments.

Abstract: Apparatus and a process for manufacturing plastic shells having decorative features thereon includes a method for casting thermoplastic material against a heated mold by use of a combination mask and container unit (hereinafter referred to as the combination unit) that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with sealing edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit of a first color. The combination unit is separated from the mold which is then processed to a higher fusion temperature and a base layer of contrasting thermoplastic material is cast thereon to be bonded to the recess material prior to cooling and stripping the mold.

Abstract: Apparatus for manufacturing a multitude of thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a mold heating chamber with a tube sheet heating assembly operative to provide a hot air flow pattern with a profile which matches the outer profile of one of a plurality of molds that are selectively placed in the mold heating chamber thereby to uniformly heat a casting surface of the mold by an energy efficient process.

Abstract: Apparatus for manufacturing plastic shells having decorative features thereon includes a combination mask and container unit that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with seal edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit.

Abstract: A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold an

Abstract: A method for heating a plurality of molds for casting heat fusable thermoplastic material each of the molds having casting surfaces and each of the molds having outer mold profiles which differ and wherein the molds are moveable into a mold chamber including the steps of providing a hot air distributor with different tube length profiles thereon; advancing a selected mold into the heating chamber and indexing the distributor to selectively match the outer profile of a selected mold with a selected tube length profile and directing hot air through the selected tube length profile for uniformly raising the temperature of the selected mold and casting heat fusable thermoplastic material in the heated mold to cause the heat fusable thermoplastic to adhere to the casting surface.

Abstract: Apparatus and a process for manufacturing multiple color thin walled hollow shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a powder box divider to form two or more compartments in a powder charge box and means for joining the chrage box divider end-to-end with a mold separation edge on an open-ended heated mold for separating the mold into two or more sections; each compartment of the charge box has a different color powder. The charge box and mold are joined and then are rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resulting shell of cured material.

Abstract: Apparatus and a process for manufacturing thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a plurality of powder boxes and an open-ended heated mold. Each charge box is carried by an indexable carousel which has a drive motor controlled by a programmable controller to position the carousel to off-load a given color to a powder casting mold carrier which is associated with means for sequentially and continuously (1) preheating a mold; (2) dumping powder from an off-loaded color box into a heated mold; (3) curing the cast powder in the mold; (4) cooling the mold; and (5) stripping the part from the mold.

Abstract: A mold assembly for manufacturing composite plastic products includes a mold cavity part and a lid, which is joined to form a cavity for foam precursors. The precursors expand in the cavity in a known manner to fill the cavity with a suitable layer of foamed material, such as foamed urethane. The mold cavity supports an exterior shell and the lid supports an insert for reinforcing a finished composite product. A sleeve is integrally formed on the preformed shell and it in turn is located within an access port formed through wall of the cavity part to define a slideway for receipt of a pour head extension. The extension is selectively clamped and unclamped with respect to the shell sleeve by an inflatable seal clamp which is formed as an annular ring with a pressurizable passage connected to a source of selectively applied pressure.

Abstract: A non-penetrating roof structure or system and method comprising a roof deck, a plurality of retainers connected to the roof deck between the margins thereof, and a cover membrane extending over the roof deck and the retainers. The cover membrane is generally flexible. A kit for connecting the cover member to the roof deck comprising the battans and retainers is also provided. The cover membrane is affixed to the deck at the margins and connected to the roof deck between the margins by the retainers. The cover member is imperforate over the retainers and the deck.

Abstract: Apparatus and a process for manufacturing multiple color thin-walled hollow sheels for parts such as automobile door panels, consoles and instrument panels from dry thermoplastic plastisol includes a supply box with a divider to form two or more compartments in the box. The box divider cooperates with selectively positioned split mold parts defining a separation in an open-ended heated mold for separating the mold into two or more sections. Complementary open ends of the charge box and mold are joined. Then the apparatus is rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resultant shell of cured material; thereafter the powder box is removed and the split mold parts are joined to clamp cast shell segments for fusion at a joint line.

Abstract: Apparatus for manufacturing multiple color thin-walled hollow shells for parts such as automobile door panels, consoles and instrument panels from dry thermoplastic plastisol includes a supply box with a divider to form two or more compartments in the box. The box divider cooperates with selectively positioned split mold parts defining a separation in an open-ended heated mold for separating the mold into two or more sections. Complementary open ends of the charge box and mold are joined. Then the apparatus is rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resultant shell of cured material; thereafter the powder box is removed and the split mold parts are joined to clamp cast shell segments for fusion at a joint line.