Abstract: An interior energy absorbing panel for the passenger compartment of a motor vehicle has a thermoplastic skin, a thermoplastic retainer, a thermoplastic air duct, and an energy absorbing rigid polyurethane foam core which is reaction injection molded about the air duct and to the skin and retainer without requiring any added adhesive. When the skin is of the soft type, a layer of semirigid polyurethane foam is reaction injection molded between the skin and the energy absorbing foam core to impart a soft feel to the skin and protect the energy absorbing foam core from indentation during normal use.

Abstract: Apparatus and a process for manufacturing plastic shells having decorative features thereon includes a method for casting thermoplastic material against a heated mold by use of a combination mask and container unit (hereinafter referred to as the combination unit) that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with sealing edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit of a first color. The combination unit is separated from the mold which is then processed to a higher fusion temperature and a base layer of contrasting thermoplastic material is cast thereon to be bonded to the recess material prior to cooling and stripping the mold.

Abstract: Apparatus for manufacturing plastic shells having decorative features thereon includes a combination mask and container unit that is joined to a known heated mold to deposit a first semi-cured deposit on the mold from supplies of material in the combination mask and container; the mask is configured to have a plurality of wire reinforced foot portions with seal edges configured to be aligned with the sharp edges of recesses in the mold surface defining the decorative feature; when the combination unit is inverted it casts material only on the recesses to form a semi-fused deposit.