Abstract: A multilayer window guiderail is disclosed. The window guiderail includes a rail portion having an outer edge, a rail surface and an opposing rear surface. The rail portion includes a core and an integral rail cover layer disposed on the core. The core includes a first polymer material and the rail cover layer includes a second polymer material. An apparatus for making a multilayer guiderail includes a plurality of die portions having respective cavity portions. The cavity portions are configured to define a die cavity having the shape of the guiderail, at least one of the die portions being a slidable die portion and at least one of the die portions being a fixed die portion. The parting surface of the slidable die portion is configured for sliding translation of its parting surface over the parting surface of the fixed die portion along a translation path.

Abstract: The invention is a method for producing a heat exchanger assembly including the steps of extruding a plastic and an adhesive from a co-extrusion die into a plurality of tubes spaced from each other with each tube having an adhesive disposed on its exterior surface. A plurality of corrugated air fins are serially fed into the co-extrusion die and spaced from each other by a predetermined space and ejected between adjacent tubes with the corrugations extending transversely between the tubes. The adhesive is then cured to secure the tubes to the air fins. The method proceeds by cutting the tubes at each predetermined space with a guillotine shear to produce a plurality of unified heat exchanger cores. The ends of the tubes of each core are inserted into tube slots in manifolds, and the tubes and manifolds are adhesively secured together to define a heat exchanger assembly.

Abstract: A multilayer window guiderail is disclosed. The window guiderail includes a rail portion having an outer edge, a rail surface and an opposing rear surface. The rail portion includes a core and an integral rail cover layer disposed on the core. The core includes a first polymer material and the rail cover layer includes a second polymer material. An apparatus for making a multilayer guiderail includes a plurality of die portions having respective cavity portions. The cavity portions are configured to define a die cavity having the shape of the guiderail, at least one of the die portions being a slidable die portion and at least one of the die portions being a fixed die portion. The parting surface of the slidable die portion is configured for sliding translation of its parting surface over the parting surface of the fixed die portion along a translation path.

Abstract: The invention is a method for producing a heat exchanger assembly including the steps of extruding a plastic and an adhesive from a co-extrusion die into a plurality of tubes spaced from each other with each tube having an adhesive disposed on its exterior surface. A plurality of corrugated air fins are serially fed into the co-extrusion die and spaced from each other by a predetermined space and ejected between adjacent tubes with the corrugations extending transversely between the tubes. The adhesive is then cured to secure the tubes to the air fins. The method proceeds by cutting the tubes at each predetermined space with a guillotine shear to produce a plurality of unified heat exchanger cores. The ends of the tubes of each core are inserted into tube slots in manifolds, and the tubes and manifolds are adhesively secured together to define a heat exchanger assembly.

Abstract: An apparatus and method for customizing the pressure within an inflatable cushion of an air bag module is provided. The method comprises determining whether additional venting of an air bag is required. A sensing and diagnostic module will receive its relative inputs from a plurality of sensors and will determine whether vents in an inflatable cushion should be opened to allow diffusion of an inflation gas. The apparatus allowing vents to open at specified times to allow for diffusion of the inflation gas.

Abstract: An apparatus and method for customizing the pressure within an inflatable cushion of an air bag module is provided. The method comprises determining whether additional venting of an air bag is required. A sensing and diagnostic module will receive its relative inputs from a plurality of sensors and will determine whether vents in an inflatable cushion should be opened to allow diffusion of an inflation gas. The apparatus allowing vents to open at specified times to allow for diffusion of the inflation gas.

Abstract: A cover for an air bag module is provided. The cover comprises a polymeric sheet and one or more thinned portions. The polymeric sheet has a first surface and a second surface and includes a plurality of cells formed therein. A skin is formed on at least the first surface. The thinned portions are formed in the second surface and define a weakened region of the cover.

Abstract: A multi layer thermoplastic polymer alloy is provided. The multi layer alloy includes a skin of thermoplastic polymer alloy having non-polar segments and a tie-layer having non-polar segments and polar functional groups. The non-polar segments of the tie-layer are bondable with the non-polar segments of the thermoplastic polymer alloy skin. Similarly, the polar functional groups of the tie-layer are bondable or reactable with a surface layer.

Abstract: In one embodiment, the method to produce a foamed material with variable cross-linking comprises mixing a first resin, a first blowing agent, and a first cross-linking agent to form a first mixture and mixing a second resin, a second blowing agent, and a second cross-linking agent to form a second mixture and cross-linking the first mixture and the second mixture such than the amount of cross-linking in the first mixture differs from the amount of cross-linking in the second mixture. The first mixture and second mixture may be co-extruded to form an extrudate having a varying amount of cross-linking across the thickness of the extrudate. The blowing agent is activated to result in a foamed material.

Abstract: A multi layer thermoplastic polymer alloy is provided. The multi layer alloy includes a skin of thermoplastic polymer alloy having non-polar segments and a tie-layer having non-polar segments and polar functional groups. The non-polar segments of the tie-layer are bondable with the non-polar segments of the thermoplastic polymer alloy skin. Similarly, the polar functional groups of the tie-layer are bondable or reactable with a surface layer.

Abstract: A cover for an air bag module is provided. The cover comprises a polymeric sheet and one or more thinned portions. The polymeric sheet has a first surface and a second surface and includes a plurality of cells formed therein. A skin is formed on at least the first surface. The thinned portions are formed in the second surface and define a weakened region of the cover.

Abstract: A foamed thermoplastic resin fiber reinforced part is provided. The part comprises a member formed of thermoplastic resin, a plurality of cells and a plurality of reinforcing fibers dispersed within the member, and a skin formed on at least one exterior surface of the member. The skin is substantially devoid of cells. Here, the reinforcing fibers have a length of about 25 mm in an amount of about 10% by weight of the foamed thermoplastic resin fiber reinforced part. At least one of a cell density and a cell size of the plurality of cells is inversely proportional to the amount of the reinforcing fibers dispersed within the member.

Abstract: A vehicle seat connection (18) has particular utility for mounting a headrest support assembly (14) on a seat back frame (12). The connection assembly (18) includes first and second plastic seat components embodied by first and second connectors (50, 52) that are injection molded in situ over enlarged flanges (56, 58) of first and second ends (44, 46) of a connector link (42) which has an intermediate portion (48) extending between its ends. The connector link is movable with respect to both the first and second connectors (52, 52) to move the headrest upwardly and forwardly upon rearward movement of a vehicle seat occupant.

Abstract: Apparatus for pulsating gas-assisted injection molding hollow tubular plastic parts includes the injection of a molten plastic into a mold cavity in an amount less than the cavity volume and in separate molten plastic flows that flow along the cavity and ultimately unite in a solidifying fusion welding state at an interface. A pressurized gas is injected into the molten plastic to form a central void in the molten plastic extending to opposite sides of the interface leaving a voidless solidifying fusion weld section encompassing the interface. The gas pressure acting on the opposite sides of the interface is trapped and then alternately increased and decreased by a separate gas injection that creates gas pulsations that effect shifting of the molten weld section in opposite directions to force intermingling of the plastic molecules therein and across the interface to enhance the strength of the fusion weld section on solidification and eliminate appearance knit lines.

Abstract: Tooling and method for gas assist injection molding of plastics material into a hollowed part in which a mold chamber formed between stationary and movable mold tools is initially charged with an inert gas to provide a resistance force against the flow front of a short shot of plastics melt subsequently injected into the cavity and supplied with a pressurized assist gas so that the velocity of the flow front of the short shot expanded by the assist gas in the mold chamber is modulated by the controlled release of the retarding chamber charge gas to prevent blow out of the short shot while eliminating flow hesitation lines to improve molded part appearance and uniformity of part wall thickness.

Abstract: Method and apparatus for pulsating gas-assisted injection molding hollow tubular plastic parts includes the injection of a molten plastic into a mold cavity in an amount less than the cavity volume and in separate molten plastic flows that flow along the cavity and ultimately unite in a solidifying fusion welding state at an interface. A pressurized gas is injected into the molten plastic to form a central void in the molten plastic extending to opposite sides of the interface leaving a voidless solidifying fusion weld section encompassing the interface. The gas pressure acting on the opposite sides of the interface is trapped and then alternately increased and decreased by a separate gas injection that creates gas pulsations that effect shifting of the molten weld section in opposite directions to force intermingling of the plastic molecules therein and across the interface to enhance the strength of the fusion weld section on solidification and eliminate appearance knit lines.

Abstract: A mounting panel is provided for mounting a window and a window regulator in a vehicle door. The mounting panel is comprised of a one-piece plastic molded member having a central planar mounting member adapted to mount the window regulator, and a plurality of spaced apart spokes molded integrally with the center drill plate and radiating generally forward and rearward therefrom to mount the guide channel receiving the edges of the window. The window guide channels are preferably integrally molded with the radiating spokes. The spokes are hollow tubular members of generally circular cross-section. The molded plastic mounting panel also has a plurality of integrally molded arm rest supports which project laterally therefrom and are adapted to support an arm rest structure of the vehicle door. The plurality of apertured mounting brackets are molded integral with the spokes for receiving fasteners by which the mounting panel is mounted on the vehicle door.

Abstract: A mounting panel is provided for mounting a window and a window regulator in a vehicle door. The mounting panel is comprised of a one-piece plastic molded member having a central planar mounting member adapted to mount the window regulator, and a plurality of spaced apart spokes molded integrally with the center drill plate and radiating generally forward and rearward therefrom to mount the guide channel receiving the edges of the window. The window guide channels are preferably integrally molded with the radiating spokes. The spokes are hollow tubular members of generally circular cross-section. The molded plastic mounting panel also has a plurality of integrally molded arm rest supports which project laterally therefrom and are adapted to support an arm rest structure of the vehicle door. The plurality of apertured mounting brackets are molded integral with the spokes for receiving fasteners by which the mounting panel is mounted on the vehicle door.

Abstract: A gas injector having a retractable nozzle with linear gas feed passage therethrough for a gas assist plastics injection molding machine. The injector interfaces with the injection molding tool and has a nozzle with a tip that, in a forward position, protrudes through a port therein leading into the tool cavity or a runner system leading into the cavity for gas injection during molding. The nozzle tip is connected by a nozzle body to a base that is operatively mounted in an actuator housing. The base is connected to an in-line gas routing extension of the nozzle that projects through the outer cover of the housing. The extension is coaxial with an internal spring that seats on the base and holds the nozzle tip in a gas injection position resisting the force of plastics injection pressure.

Abstract: Gas transmission plugs are placed in a supporting strip portion in plastics injection mold tooling so that an appropriate gas assist injection location can be readily selected, and mated, with a gas injection nozzle thereby eliminating the requirement for pre-drilling mold tooling with gas injection points and removing the tooling from the press so that a gas injection nozzle can be installed relative to the selected injection location. The plugs can be made from porous metal or ceramic with pores that are so small that plastics cannot enter the plug to cause pore clogging. Also, linear gas transmitting passages can be laser beam drilled through plugs of steel or other material with diameters that are sufficiently minute to prevent entry of plastics melt and resultant clogging.