Abstract: A method of molding automotive interior trim parts wherein a block of a predetermined thickness and area of a suitable grade of fiber or other suitable insert material is pressed into a molten vinyl shell during the latter's curing cycle. The fiber block or insert becomes fused to the vinyl shell and may expand to approximately three times its original thickness to serve as the backing and mounting insert for the finished two-component interior trim part.

Abstract: A cover assembly for an airbag restraint system has a smooth, grained, plastic cover and a load bearing insert for covering a housing for an airbag and a gas generator which includes an inflatant for the airbag for deploying the airbag through the smooth, grained plastic outer cover member without rupturing the cover member at weakened sections therein and wherein a carriage is formed in an insert opening having a cutter thereon between the cover and the air bag; the cutter has cutting edges thereon directly contacting the cover assembly for perforating the cover during inflation of the airbag so as to form a self-piercing cover assembly which will be cut to form an opening through the cover assembly through which the airbag is deployed; the self-piercing occurring as the airbag is inflated and solely in response to such inflation prior to deployment of the airbag into the passenger compartment.

Abstract: A door assembly for an opening through which an inflatable restraint safety device may be deployed including a frame for supporting an inflatable restraint safety device and an opening presented in the frame, a door is disposed in the opening and is capable of rapidly moving so that the inflatable restraint device may be deployed through the opening, the door includes an impact plate portion and a foam portion bonded to the impact plate portion with the foam portion including a microcellular component having a first predetermined density and an integral outer skin component distinct from the microcellular component and formed integral with the microcellular component and which has a second predetermined density which is greater than the first predetermined density of the microcellular component for providing an aesthetically pleasing non-separable surface on the microcellular component.

Abstract: A method for integrally molding a preassembled door within an instrument panel to provide a cover for a safety air cushion device includes the steps of molding the plastic instrument panel about and over the door in situ of a mold cavity and thereafter the step of removing a portion of the instrument panel which overlies the door to provide an opening therein to expose the door for opening movement with respect to the instrument panel upon deployment of the air cushion device. The invention further includes the resultant structure of an integrally molded door and instrument panel assembly having an opening formed in the instrument panel assembly for both defining a ledge to support the door and to define a path for impacting an air cushion device against the door to cause the door to be lifted from its integrally molded seat relationship on the ledge for further deployment of the air cushion device into the passenger compartment of a vehicle.

Abstract: A furnace flue gas draft inducer outlet box assembly is provided for connecting an inducer housing to a vent pipe, and comprises a plurality of differently directed openings to allow the vent pipe to be connected thereto in one of a plurality of different orientations, thereby facilitating ease of installation of the furnace. When incorporated with a condensing furnace, the inducer outlet assembly further comprises a condensate collecting system for collecting a return flow of condensate formed in a vent pipe and for delivering the condensate out of the inducer housing to prevent contact with the inducer motor, wheel and the like.