Abstract: An apparatus for deploying an air bag through an automotive dash panel (12) includes an air bag door (16) integrally formed in the panel and defined by a door perimeter including a frangible edge (18) of reduced cross section. A dispenser (20) supports the air bag (24) behind the door. A metal reaction plate (28) is positioned between the air bag (24) and the door (16). When the air bag inflates, it forces the reaction plate (28) to bend around a horizontal hinge line (36). As the reaction, plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers (50) limit how far the door can travel during air bag inflation.

Abstract: An air cell support system for vehicle seat and mattress applications includes an air cell constructed from facing sheets of flexible material that are sealed along their marginal edges. One of the sheets is impermeable and the other of the sheets is perforated to direct air from the air cell for ventilating an occupant support surface while providing a source of pressure for inflating the air cell.

Abstract: A vehicular seat (10) including a seat bottom (12) and a seat back (14). In one embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded frame (16) including side walls (18) extending generally upwardly from a bottom panel (20). A support mat (32) comprising fabric/rubber webbing extends across a central cut-out region (28) in the bottom panel (20) and supports an inflatable cushion (48) comprising a series of air cells (50). An extensible upholstery or trim cover layer (56) covers the inflatable cushion (48) and is joined to the frame (16). In a second embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded shell (62). An intermediate layer (64) of plastics material is provided on the shell (62) beneath an upholstery layer (68). An opening in the shell (62) allows the intermediate layer (64) to be expanded outwardly from the shell (62) as the pressure within the shell (62) is increased.

Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a door perimeter including a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates, it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.

Abstract: A system of inflatable air cells (3,10) is constructed and installed in a seat (2) at locations that are strategic to the comfort of the user. The air cells are selectively pressurized to a desired comfort level and in addition, in response to a vehicle impact, are controlled by valves (62, 80) to have a occupant impact protection pressure therein for protecting the occupant against impact with the vehicle seat.

Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.

Abstract: A low energy consumption valve module (16) includes low energy consumption valves (20) having either bimorphs or monomorphs defined by a circular diaphragm (21) carrying one or more piezoelectric discs (22) (23) operative to position a sealing disc (36) for sealing a valve seat (34). In one embodiment the discs are energized across conductive seals (51,52,54,56) and in another embodiment the discs are energized by a pair of flexible conductors (150). A process for making the bimorphs or monomorphs comprises a tape cast process in which ceramic with piezoelectric properties is shaped without machining. A process for making the valve module providing a valve body (200) and valve cover (202) of either laser energy transparent or laser energy absorbent polyimide material that are joined at a line to line contact (210) and sealed upon application of a laser welding beam to the line to line contact between the valve body and the valve cover at the perimeter thereof.

Abstract: A vehicular seat (10) including a seat bottom (12) and a seat back (14). In one embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded frame (16) including side walls (18) extending generally upwardly from a bottom panel (20). A support mat (32) comprising fabric/rubber webbing extends across a central cut-out region (28) in the bottom panel (20) and supports an inflatable cushion (48) comprising a series of air cells (50). An extensible upholstery or trim cover layer (56) covers the inflatable cushion (48) and is joined to the frame (16). In a second embodiment, the seat bottom (12) and seat back (14) are formed from a blow molded shell (62). An intermediate layer (64) of plastics material is provided on the shell (62) beneath an upholstery layer (68). An opening in the shell (62) allows the intermediate layer (64) to be expanded outwardly from the shell (62) as the pressure within the shell (62) is increased.

Abstract: An apparatus for deploying an air bag through an automotive dash panel includes an air bag door integrally formed in the panel and defined by a frangible edge of reduced cross section. A dispenser supports the air bag behind the door. A metal reaction plate is positioned between the air bag and the door. When the air bag inflates it forces the reaction plate to bend around a horizontal hinge line. As the reaction plate rotates it concentrates inflation force along a lower portion of the frangible door edge. This helps predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers limit how far the door can travel during air bag inflation. A stop member may be included to limit reaction plate bending.

Abstract: A skin for an automotive interior panel has a main body portion for covering most of the panel and an air bag cover portion for covering the panel portion that the air bag deploys through. Casting a first plastic material against a first portion of a heated mold surface forms the main body skin portion. Casting or spraying a plastic material against a second portion of the heated mold surface forms the air bag cover skin portion. The mold surface portions may be confined from one another by a partition or by masking one portion while casting against the other. The main body and air bag cover skin portions include adjacent edges that extend along the air bag cover portion periphery. The two skin portions are joined together along their adjacent edges while still on the heated mold. An air bag deployment tear seam is formed by first casting a tear seam gap in the cover portion then spraying or casting a relatively weaker material into the gap.

Abstract: An air cell system for vehicle seat and mattress applications includes an air cell constructed from facing sheets of flexible air-impermeable material that are sealed along their marginal edges. A gap is provided at a prescribed location along the seam to accommodate and air tube. The portion of the air tube received in the gap has a generally diamond shaped cross section including a central tubular region and opposed lateral side sections that taper radially outwardly in order to occupy correspondingly shaped regions of the gap. The shaped end of the air tube is sealed to the facing cell layer material to provide an airtight, unstressed seal therebetween.

Abstract: An air bag cover door assembly utilizes a releasable fastener along each side of the air bag cover door to provide a predetermined opening characteristic for the cover door. The fasteners can be hook and loop tape, mechanical interlocks, adhesive strips, etc., with one half of each fastener secured to the inside surface of the cover door and the other half secured to a substructure, such as a dashboard pad retainer, in mating engagement with the first half. The fasteners are located along the sides of the cover door proximate the hinging axis of the cover door so that expansion of the air bag causes the cover door to initially hinge along a line extending between the engaged fasteners and then causes the fasteners to separate, allowing the cover door to swing open fully about its hinging axis.

Abstract: A skin or shell is disclosed for use in a mold process in which the skin or shell is placed in a mold in which foam precursors are directed onto the skin for reaction thereagainst to form a foam layer thereon; the skin includes integral connector features thereon adapted to be connected to the mold for stabilizing the location of the skin within the mold so as to prevent wrinkling of the skin during the mold process.

Abstract: An interior trim product has an opening therein formed to overlie an air bag restraint assembly housed in the trim product. The air bag restraint assembly includes a canister for generating gas to inflate an air bag for deployment into the passenger compartment of a motor vehicle. The opening is closed by a door having a vinyl outer covering matching the aesthetic appearance of the outer surface of the interior trim product. First and second substrates formed in the interior trim product and on the door support two hook and loop fastener strips each of which is connected to one of the substrates to form a tamper proof connection for holding the door in place prior to air bag deployment.

Abstract: A vehicle steering wheel has a decorative panel concealing a storage compartment for an inflatable air bag. The panel has a covering which comprises a backing plate having a U-shaped cut line framing the storage compartment and defining a cover door having a hinge line connecting the ends of the cut line U. An inner layer of foam is interposed between the backing plate and an outer skin layer. The skin has a peripheral groove outlining the door and comprises a hinge section overlaying the hinge line and a weakened tear seam line overlying the cut line. The groove is cut through at the bottom along the tear seam line but not along the hinge section. Inflation of the air bag will force the door outwardly, fracturing the foam layer along the tear seam line to swing the door away from the opening about the hinge section to enable deployment of the air bag outwardly of teh panel. The cuts in the panel layers can be made before or after a molding process.

Abstract: A vehicle dash board comprises a support mounting a storage compartment for an inflatable air bag, a resilient covering for the dash board, and an opening in the support for enabling deployment of the air bag upon inflation outwardly of the dash board. A decorative panel carried by the support and concealing the storage compartment comprises a backing plate having a U-shaped cut line framing the opening and defining a door. A rod is carried by the support and engages the backing plate along a line connecting the ends of the cut line at the top of the U to provide a hinge line for the door. A resilient layer of material overlies the backing plate and comprises an outer flexible skin layer and an intermediate resilient foam layer bonded to the support and skin. The skin layer has an end flap on its free side opposite the hinge line which is stitched to the adjacent dash board covering so as to define a tamper proof door seam which cannot be pried open either by intention or inadvertance.

Abstract: A skin or shell for use in a mold process in which the skin or shell is placed in a mold in which foam precursors are directed onto the skin for reaction thereagainst to form a foam layer thereon; the skin includes integral connector features thereon adapted to be connected to the mold for stabilizing the location of the skin within the mold so as to prevent wrinkling of the skin during the mold process.

Abstract: A mold assembly for molding vinyl skin shell-covered and foam-filled products, such as an automotive instrument panel, wherein waste portions of the shell and foam are eliminated from the molded product. This eliminates having to manually trim such portions from the finished product after molding. Specifically, compressible foam or silicone rubber gaskets or spacers of predetermined shaped, such as the shape of an opening suitable for a radio speaker, are placed in the mold and compressed between the mold lid and the bottom surface of the mold cavity.

Abstract: An instrument panel assembly, for mounting between the front support pillars of a vehicle, includes a panel body with openings for supporting and displaying instruments and gages and extending transversely between two front support pillars of a vehicle, with the panel body having first and second ends, and the panel body further includes adjustable, compressible bellows disposed at the terminal ends of the panel body for adjustment between extended and compressed positions to provide flush engagement with the front support pillars of the vehicle.

Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.