Davidson Textron Inc.

Honda Giken Kogyo Kabushiki Kaisha

Morton International, Inc.

Davidson Technology Center

James R Pritchard

William McHugh Humphrey, Jr

Wayne C Salisbury

Hitoshi Higuchi

Lawrence R Nichols

Makoto Kan

Scott L Hansen

Wayne D LaRoche

Iwao Imaizumi

Mary K Marshall

Gene Shope

Alan Choiniere

Michael J Provencher

Brian R Hatter

Interior trim panels and method for manufacturing such panels using silaceous materials

An interior trim component, such as a door panel, having an outer skin backed by a low density molded mat foam substrate and an energy absorbing foam backing is manufactured in a single mold tool in a multiple stage foaming operation in which the outer skin and a glass reinforcement mat are positioned in the mold cavity and a mold insert corresponding to the energy absorbing foam layer is mounted to the lid of the mold tool. A polyurethane precursor mixture is poured into the open mold and the lid closed to generate the low density molded mat substrate. The mold is opened and the mold insert removed and a second urethane precursor mixture is poured onto the substrate and the mold closed to generate the energy absorbing foam backing within the space of the mold cavity previously occupied by the mold insert.

Method for manufacturing an automotive trim product

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.

Panel with integral energy absorber and air duct

A solvent flush reaction injection molding mixhead has a mixing chamber with a solvent inlet port in one end and a chemical outlet port in an opposite end. A pair of hydraulically operated chemical injectors are connected to the mixing chamber between the solvent inlet port and chemical outlet port to inject liquid reaction molding chemicals at high pressure through injector ports into the mixing chamber. The mixed chemicals are delivered through the chemical outlet port to a spray wand on the mixhead for application to a mold surface or an object requiring a foam coating. A flush valve is associated with the solvent inlet port and is moveable from a closed position to block the solvent inlet port while the chemicals are injected into the mixing chamber, and an open position where liquid solvent under a high pressure is supplied through turbulator ports into the mixing chamber to clean and flush any remaining mixed chemicals from the flush valve, the mixing chamber including the chemical injector ports, and the spray wand.

Solvent flush reaction injection molding mixhead

A nozzle assembly (16), for spraying a liquid such as a urethane prepolymer on a substrate, has a liquid spray nozzle (28) with a center line (56). Air nozzles (30), with center lines (62) that are substantially parallel to the center line (56) of the liquid spray nozzle (28), are provided in the nozzle assembly (16) around the liquid spray nozzle. Air passing from the air nozzles (30) surrounds and encloses the liquid spray and decreases the size of the liquid spray fan pattern (58 or 70). The air spray nozzles (30) can be positioned in the nozzle assembly (16) to change the shape of the liquid spray fan pattern (58 or 70) as well as the size. Mixing of air and liquid is minimized by spraying air and liquid in parallel paths.

Spray wand with spray fan control

A cover for an inflatable air bag housing is formed of integrally molded resinous plastic material and defined therein is a hinge area and a thin fracture line forming a door which pivots to an open position upon fracture of the cover along the fracture line when an air bag is inflated. A metal reinforcing element is embedded in the resinous plastic material and includes segments diverging and below the hinge area forming an open space or void which is filled in with a low density collapsible, energy absorbing, rigid foam which exhibits minimal spring back. The filler helps prevent sagging or read-through of the cover above the void when prolonged exposure to heat and sun is experienced. Moreover, the foam filler absorbs energy during bag deployment and aids in preventing plastic resin from leaking into the void space during the initial fabrication of the cover as the metal reinforcement element is molded in place.

Cover for an inflatable air bag housing

A RIM molded energy absorbing polyurethane rigid foam prepared from reacting inter alia a graft polymer polyol and an organic isocyanate using water as the blowing agent.

RIM molded energy absorbing polyurethane foam

Growing community of inventors

Somersworth, NH, United States of America

James R Pritchard