Abstract: A hollow plastic article of a one-piece construction formed from a molten plastic resin by a gas-assisted injection molding system wherein the article is designed in such a way that any gas channel read through is hidden at a “Class A” convex surface thereof. The article includes a hollow body section and a solid wall section which extends downwardly and rearwardly from a front wall of the hollow body section. The solid wall section and the front wall immediately adjacent to the solid wall section define a convex, sink-free, exterior surface of the article to hide any gas channel read through.

Abstract: An air bag cover assembly is provided. The assembly includes a front panel having inner and outer surfaces and a switch module attached to the inner surface of the front panel. The switch module includes a front plate and a back plate attached to and spaced apart from the front plate to define a switch pocket therebetween and a switch disposed in the switch pocket. The front plate has a plurality of spaced ribs integrally formed at and projecting from an outer surface of the front plate towards the inner surface of the front panel. Distal ends of the ribs are shaped to substantially conform to the inner surface of the front panel so that pressure on the outer surface of the front panel at a switch activation area is transmitted by the ribs to activate the switch.

Abstract: A mold for use in a gas-assisted injection molding system includes an ejector pin subsystem including a split pin which partially blocks the flow of molten plastic through a secondary runner, helps to eject solid plastic from the mold, and helps to define an article-defining cavity and the secondary runner in the mold. A first spill cavity is flow coupled by the secondary runner to the article-defining cavity. The split pin together with other ejector pins are mounted on an ejector plate to move therewith between extended and retracted positions. A second spill cavity is flow coupled by a tertiary runner to the first spill cavity if needed. The split pin, as well as the other ejector pins mounted on the ejector plate, eject plastic from the article-defining cavity, the spill cavities, and the secondary and tertiary runners in the extended position of the ejector plate.

Abstract: A mold for use in a gas-assisted injection molding system includes an adjustable overflow pin assembly which includes a conical stack of shims which are removably secured to an ejector pin to move therewith within a conically-shaped spill cavity flow-coupled by a secondary runner to an article-defining cavity of the mold. The mold also includes a blocking pin assembly which together with the adjustable overflow pin assembly are mounted on an ejector plate to move therewith between extended and retracted positions of the ejector plate. The blocking pin assembly includes a blocking pin which is slidably fit within the second mold half to move relative to the ejector plate between an extended blocking position to block the flow of molten plastic through the secondary runner and a retracted position to allow the flow of molten plastic through the secondary runner and into the spill cavity.