Davidson Textron Inc.

Lavidson Textron Inc.

John Muller

Reza Kargarzadeh

Donald Casteel

A trim panel having an integral handle is made using a subassembly comprising a structural substrate that has a handle hole and a handle frame that spans the handle hole. The subassembly is mounted on a pneumatic buck and a sheet of pliable and stretchable expanded vinyl plastic is then draped over the subassembly to form a decorative cover for the trim panel. The plastic sheet is then vacuum drawn against the top of the subassembly and partially around the handle frame. Draped portions of the plastic sheet between the handle frame and the handle hole, are then cut and trimmed, to complete the wrapping of the handle frame and the edge of the handle hole. The cut ends of the draped portions wrapped around the handle frame are tucked in a longitudinal slot in the underside of the handle frame. The plastic sheet can be also be drawn completely around the handle frame and the pneumatic buck can be provided with a cusp shaped surface aligned with the handle hole to reduce stretching of the plastic sheet when it is drawn around the handle frame.

Method of manufacturing a trim panel having a handle

A method of simultaneously vacuum forming a plastic article and integrally joining a device thereto is disclosed wherein a lock defining surface is formed on an anchoring end of the device, a heat activated adhesive is applied to the lock defining surface, and air is drawn through vacuum holes in the mold surface that defines the shape of the article and is also drawn through vacuum holes in the lock defining surface to draw a heated sheet of thermoplastic material onto the mold surface and also into interlocking relationship with the lock defining surface to form the article and to mechanically interlock and adhere the device to the formed article.

Method of making vacuum formed article with integrally joined device

A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a partial recess with raised side ribs joined to a removable plug with raised side ribs and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part. The raised side ribs combine to form spaced parallel recesses in the tube to form an inner surface on a 360.degree. with a smooth feel. The article formed by the method and apparatus includes a shell of thermoplastic material which is fused and cured and which includes a generally planar segment having an integrally formed tubular segment thereon for defining the outer skin surface of a full 360 degree handle with no raised, rough feel parting lines therein.

Method for forming smooth handle

A self-licking stud assembly including male and female segaments. The male segment includes a base for mounting or being integrally molded on a panel member to be joined with a second panel member in a side-by-side relationship, a central stem extending from teh base, with a plurality of equally spaced deflectable fingers formed on the end thereof so as to extend outwardly and toward the base. The female segment includes a base for mounting or being integrally molded on the second panel member, a flange or collar formed on one side of the base, and an opening through the base and the collar, with a frustoconically shaped surface formed on the inner surface of the collar. The outer edges of the fingers are selectively shaped to lockingly cooperate with the frustoconically shaped surface once the fingers are urged through the opening.

Two-piece stud assembly

A fastener system for connecting first and second parts together includes a female fastener having a retention slot therein with an entrance portion, a stop portion and a fastener gripping segment located intermediate said entrance portion and said stop portion; a male fastener has an integral extension thereon insertable into said entrance portion and movable laterally of the slot to an interlocked position at the stop portion. The male fastener includes first surface means thereon engageable with the gripping segment for holding the male fastener in a stop position, and said male fastener further includes second surface means thereon to interlockingly connect the female fastener to the male fastener. The component parts of the fastener system are configured to be formed by use of die members separable in a straight draw.

Self locking attaching system

For automotive interior trim molding assemblies having a vinyl skin shell, a reinforcement insert, and an intermediate reaction type polyurethane foam composition, a vinyl skin shell which has a gasket-type peripheral edge formed thereon for abutting cooperation with the reinforcement insert to prevent leakage of the foam therepast during the foam reaction period in a reaction mold. The gasket-type peripheral edge is formed on the otherwise thin shell by a tear edge, against which plastisol builds up in a substantially triangular cross section during the shell molding period in a heated slush mold.

Plastic shell for foam moldings

An improved mold assembly which has a cavity mold part and a cover which form a space into which foam precursors are poured and the cover carries a mold insert which is bonded to the foam formed in the mold space; the cover carries a pour spout and a seal for preventing foam leakage from the space wherein the improvement comprises: means including a pour hole and a rotatable tube extending through said pour hole for defining a pour spout having an inboard end located within the space when the mold assembly is closed; seal means in surrounding sealing relationship with said inboard end of said rotatable tube; and means operative when the cover is closed and when the tube is located in the pour space for holding the insert within a desired variation of a designed location in said space and for holding the insert against said seal means to prevent foam leakage through the pour hole.

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Englewood, TN, United States of America

John Muller