Abstract: A gas injection apparatus for use with a gas assisted injection molding system. The gas injection apparatus includes a mold part defining an elongated bore communicating upstream with a source of gas and downstream with a mold cavity, and an elongated pin positioned in the bore and coacting with the bore to define a gas flow passage therebetween for movement of gas from the gas source to the mold cavity. The bore and pin include first, second and third corresponding portions. The pin and bore define an annular axial clearance in the first portion, a close fit with an axial linear passage in the second portion and an annular axial passage in the third portion. This arrangement ensures that the pin will remain concentric with respect to the bore so as to discourage entry of resin into the annular axial passage.

Abstract: A method and system are disclosed for locally introducing fluid, such as a gas, at a predetermined location into molten resin downstream from a resin injection aperture to form a hollow part. The gas is utilized at the localized area to distribute the molten resin, to eliminated molded in stress and to prevent formation of sink marks in the part during resin solidification. An overflow reservoir outside of the mold cavity is filled with the resin during resin injection and then the gas is introduced into the reservoir through a fluid aperture and into the part. The reservoir creates a cocoon of solidified material to act as a seal to prevent gas leakage. One hollow body formed by the method and system includes a substantially endless hollow body portion with a fluid opening for communicating the interior of the hollow body portion with the locally introduced fluid. The hollow body provides an internal gas manifold and means for greater structural integrity.

Abstract: A system is disclosed for locally introducing fluid, such as a gas, at a predetermined location into molten resin downstream from a resin injection aperture to form a hollow part. The gas is utilized at the localized area to distribute the molten resin, to eliminated molded in stress and to prevent formation of sink marks in the part during resin solidification. An overflow reservoir outside of the mold cavity is filled with the resin during resin injection and then the gas is introduced into the reservoir through a fluid aperture and into the part. The reservoir creates a cocoon of solidified material to act as a seal to prevent gas leakage. One hollow body formed by the method and system includes a substantially endless hollow body portion with a fluid opening for communicating the interior of the hollow body portion with the locally introduced fluid. The hollow body provides an internal gas manifold and means for greater structural integrity.

Abstract: A gas assisted injection molding method and apparatus wherein articles are produced by injecting molten resin into a mold cavity and then injecting a quantity of pressurized gas into the resin to fill out the mold cavity and form a hollow in the resin. Following the injection of the gas into the resin to form the hollow, gas is injected into the resin in the mold cavity at a second location. The gas injected at the second location may either form a separate hollow within the resin or may form a passage extending through the resin for communication with the hollow formed by the gas injected at the first location. The first location is preferably the resin injection location and the second location is preferably a location communicating directly with the mold cavity. Gas is vented from the article either at the first location, the second location, or both locations.

Abstract: A unitary nozzle for use in a gas assisted injection molding process wherein the nozzle includes a central axial resin passageway, a land portion of the nozzle extends radially into the resin passageway proximate the downstream or discharge end of the nozzle to define a generally U-shaped resin passageway terminating in a U-shaped aperture at the nozzle tip, and a central gas passageway is provided on the central axis of the nozzle within the land portion and exiting the nozzle in a circular aperture embraced within the U-shaped resin aperture at the downstream end of the nozzle so that mixing of the resin and gas during the injection and venting processes is minimized and so that ingestion of resin into the gas passageway during the venting process is minimized.

Abstract: A method and apparatus for providing gas assistance in a resin injection molding process of the type in which hot resin is injected into a mold, gas is injected into the mold to displace a portion of the resin in the mold, the resin cools, the gas is vented, and the mold is opened to remove the molded part. The apparatus includes a high pressure gas storage system, a plurality of pressure control assemblies set at varying pressures and interposed between the high pressure gas storage system and the injection nozzle, and a control system which is operative to selectively communicate each of the pressure control assemblies with the injection nozzle so as to allow the delivery of gas at varying pressures to the mold to facilitate the creation of an individualized gas pressure profile to suit the particular molding requirement.

Abstract: An impact energy managing bumper structure having a configuration and component members that cooperatively provide, as a function of position along its length, predetermined levels of resilient opposition to deformation and displacement. A semirigid resilient fascia is spaced forwardly of the bumper structure, and the volume defined therebetween is filled with an integral skin urethane foam that is resiliently deformable and integrally bonded to both members.

Abstract: A method and system are disclosed for locally introducing fluid, such as a gas, at a predetermined location into molten resin downstream from a resin injection aperture to form a hollow part. The gas is utilized at the localized area to distribute the molten resin, to eliminated molded in stress and to prevent formation of sink marks in the part during resin solidification. An overflow reservoir outside of the mold cavity is filled with the resin during resin injection and then the gas is introduced into the reservoir through a fluid aperture and into the part. The reservoir creates a cocoon of solidified material to act as a seal to prevent gas leakage. One hollow body formed by the method and system includes a substantially endless hollow body portion with a fluid opening for communicating the interior of the hollow body portion with the locally introduced fluid. The hollow body provides an internal gas manifold and means for greater structural integrity.

Abstract: A gas assisted injection molding apparatus of the type in which a supply of resin is introduced into a cavity in a mold at a resin injection location and a gas injection assembly is provided to introduce gas into the mold cavity at a gas injection location removed from the resin injection location to assist the resin in filling out the mold cavity. The gas injection assembly includes a bore in the mold communicating with the mold cavity, a pin having a size to fit slidably in the bore and including a central axial passage for delivery of gas into the mold cavity through the pin, a power cylinder assembly mounting the pin for movement between an advanced gas injection position in which the pin is positioned in the bore with its forward tip in communication with the mold cavity and a retracted position in which the mold cavity is vented through the bore, and an annular edge on the pin operative to remove obstructions with each forward movement of the pin from its retracted position to its advanced position.

Abstract: A method and apparatus for gas assisted injection molding. The apparatus includes a bulk storage container; a booster receiving the gas from the bulk storage container and operating to boost the pressure to a relatively high level for delivery to a high pressure storage container; a regulator receiving the gas from the high pressure storage container and reducing the gas pressure to a desired injection pressure; and a control system for injecting the gas into the mold, at the injection pressure as determined by the regulator, thereafter reducing the gas pressure within the mold to a hold pressure, thereafter maintaining the gas in the mold at the hold pressure, and thereafter venting the mold to atmosphere. The apparatus allows the performance of two distinct injection molding methods. In the first method, the regulated gas is injected directly into the mold, is held at the injection pressure during the fill out portion of the molding cycle, and is thereafter reduced to a hold pressure.

Abstract: An injection molding method and nozzle for use therein wherein first and second variable pressures are applied to a piston of a valve mechanism of the nozzle so that a differential fluid pressure on the piston causes a tip portion of the valve mechanism to alternately open and close. In this way, the tip portion communicates the flow of resin from a nozzle body of the nozzle to an injection aperture of a mold. Differential pressure on the piston prevents a fluid which distributes the molten resin over the interior surfaces of the mold from entering the flow path of the molten resin in the nozzle body. The fluid preferably is a gas, such as nitrogen. Preferably, the piston is mounted for reciprocating movement within the nozzle body and the first pressure is provided by the resin during resin injection and the second pressure is partially applied by the nitrogen gas.

Abstract: An impact energy managing bumper structure having a configuration and component members that cooperatively provide, as a function of position along its length, predetermined levels of resilient opposition to deformation and displacement. A semirigid resilient fascia is spaced forwardly of the bumper structure, and the volume defined therebetween is filled with an integral skin urethane foam that is resiliently deformable and integrally bonded to both members.

Abstract: A vehicle spoiler includes a first rigid body part having an external surface contour, a second resiliently deformable foam body part having an external surface contour complementary to the first surface contour, and means for integrally securing the first and second body parts together. Preferably, the deformable foam body part is molded in situ on the rigid body part. A finishing groove extending between adjacent edges of the first external surface contour and the second external surface contour prevents recognition of differences between the materials and processes used to form the first and second body parts and prevents inconsistent transition between the body parts. A method for forming the spoiler includes fabrication of injection molded body shell parts bonded together by a foam material to form a rigid first body section. The rigid body section is then positioned within a molding cavity while foam material is introduced into the cavity and against engagement surfaces on the rigid body part.

Abstract: A vehicle spoiler comprises a first rigid body part having an external surface contour, a second resiliently deformable foam body part having an external surface contour complementary to the first surface contour, and means for integrally securing the first and second body parts together. Preferably, the deformable foam body part is molded in situ on the rigid body part. A finishing groove extending between adjacent edges of the first external surface contour and the second external surface contour prevents recognition of differences between the materials and processes used to form the first and second body parts and prevents inconsistent transition between the body parts. A method for forming the spoiler includes fabrication of injection molded body shell parts bonded together by a foam material to form a rigid first body section. The rigid body section is then positioned within a molding cavity while foam material is introduced into the cavity and against engagement surfaces on the rigid body part.

Abstract: A shock-absorbing bumper comprises a semi-rigid resilient fascia and a bumper bar spaced rearwardly from the fascia, the space therebetween being filled with an integral skin urethane foam which is resiliently compressible and integrally bonded to the fascia and bumper bar.

Abstract: A wheel cover installation and retention system for a wheel including a circumferential retention groove. The wheel cover includes pilot ribs for first engaging the inner surface of the wheel at a plurality of preselected positions on the wheel and preventing radial movement of the wheel cover relative to the wheel during installation, retention fingers for engaging the circumferential retention groove at a plurality of preselected locations on the wheel, and a spring member contacting the retention fingers and exerting a radially outward force on the retention fingers, thereby urging the retention fingers into the circumferential retention groove on the wheel.

Abstract: A shock-absorbing bumper comprises a semi-rigid resilient fascia and a back-up member spaced rearwardly from the fascia, the space therebetween being filled with an integral skin urethane foam which is resiliently compressible and integrally bonded to the bumper members.

Abstract: An energy absorbing steering assembly employs an elongate tubular adapter sleeve, including breakaway bolts and a bracket for mounting the sleeve on the underside of an instrument panel and at least one annular, radial sleeve flange extending inward from the side walls of the adapter sleeve, forming a reduction of the inner diameter of the adapter sleeve to a first preselected size, an elongate steering column slidably retained coaxially within the adapter sleeve, the steering column, including an annular, radial column flange extending outward from the side walls of the column, the flange being slightly smaller than the inner diameter of the adapter sleeve, a steering shaft mounted for rotation within the steering column, and elastically deformable plastic foam molded in situ to fill the cavities between the sleeve and the steering column.

Abstract: A vehicle bumper is adapted to provide energy management of impact forces. In a basic embodiment the bumper includes a fascia having a front portion adapted to receive impact forces and upper and lower flanges extending rearwardly from the front portion. A backing member is positioned rearwardly from the fascia and includes means for mounting the bumper on the vehicle. The volume bounded by the backing member and the fascia has a resiliently compressible plastic foam molded in situ and features an integral skin bonded to adjacent surfaces of the fascia and the backing member.

Abstract: A method and apparatus for staking a formable projection, for example, a tab or boss, to retain plural articles in a unitary assembly. A projection on a first article is brought into registering position with an aperture in a second article to form the assembly. The assembly is clamped by a spring-loaded clamp pad which bears against the second article and surrounds the projection. The projection is then staked by action of a tool which travels reciprocally within the clamp pad and has a tip which cooperates with the clamp pad to form a cavity of desired shape. The forming stroke of the tool is against the resistive force of the spring, which increases the clamping force of the clamp pad. The formed projection is therefore contained within the inner boundary of the clamp pad and tool tip to thereby promote uniform head formation.