Davidson Textron Inc.

Kent L Parker

Bruce A Batchelder

James C Carter

Laurent R Guadreau

George Bleau

Norman Clavette

A method of molding automotive interior trim parts wherein a block of a predetermined thickness and area of a suitable grade of fiber or other suitable insert material is pressed into a molten vinyl shell during the latter's curing cycle. The fiber block or insert becomes fused to the vinyl shell and may expand to approximately three times its original thickness to serve as the backing and mounting insert for the finished two-component interior trim part.

In-mold mating of substrate material to vinyl skin covering for the

A cover assembly for an airbag restraint system has a smooth, grained, plastic cover and a load bearing insert for covering a housing for an airbag and a gas generator which includes an inflatant for the airbag for deploying the airbag through the smooth, grained plastic outer cover member without rupturing the cover member at weakened sections therein and wherein a carriage is formed in an insert opening having a cutter thereon between the cover and the air bag; the cutter has cutting edges thereon directly contacting the cover assembly for perforating the cover during inflation of the airbag so as to form a self-piercing cover assembly which will be cut to form an opening through the cover assembly through which the airbag is deployed; the self-piercing occurring as the airbag is inflated and solely in response to such inflation prior to deployment of the airbag into the passenger compartment.

Self-piercing cover assembly for airbag

A process for molding foam products from foam precursors reacted in a mold cavity formed in part by a mold lid and which is covered by a double layer cover to maintain the surface of the lid clean during the foaming process comprising the steps of: providing a double layered cover having four working surfaces; adhering one of the working surfaces to the lid and thereafter closing the tool lid and foaming the part. The lid is opened and the cover and foam part are separated from the mold. The lid is separated from the double layer cover and foam part at a working surface of low strength adhesive; a release sheet of the cover is separated at two other working surfaces to expose a high strength adhesive for connecting the foam part to another member. The double layer cover used for practicing the process includes a foam layer adapted to have one surface thereof bonded to foam material and including a high strength adhesive backing thereon. A release sheet layer is formed on the high strength adhesive and remains thereon until a foam part is separated from the mold. The release sheet further includes a low strength adhesive on the exposed surface thereof which is adapted to be connected to the mold lid to prevent foam material build up without use of release agent coatings.

Method for forming foamed parts and a multiple layer release adhesion

A door assembly for an opening through which an inflatable restraint safety device may be deployed including a frame for supporting an inflatable restraint safety device and an opening presented in the frame, a door is disposed in the opening and is capable of rapidly moving so that the inflatable restraint device may be deployed through the opening, the door includes an impact plate portion and a foam portion bonded to the impact plate portion with the foam portion including a microcellular component having a first predetermined density and an integral outer skin component distinct from the microcellular component and formed integral with the microcellular component and which has a second predetermined density which is greater than the first predetermined density of the microcellular component for providing an aesthetically pleasing non-separable surface on the microcellular component.

Self-skinned foam component for an inflatable restraint door assembly

A method for integrally molding a preassembled door within an instrument panel to provide a cover for a safety air cushion device includes the steps of molding the plastic instrument panel about and over the door in situ of a mold cavity and thereafter the step of removing a portion of the instrument panel which overlies the door to provide an opening therein to expose the door for opening movement with respect to the instrument panel upon deployment of the air cushion device. The invention further includes the resultant structure of an integrally molded door and instrument panel assembly having an opening formed in the instrument panel assembly for both defining a ledge to support the door and to define a path for impacting an air cushion device against the door to cause the door to be lifted from its integrally molded seat relationship on the ledge for further deployment of the air cushion device into the passenger compartment of a vehicle.

Method of forming a plastic panel for covering an inflatable restraint

A method and apparatus for manufacturing a composite article by use of a mold core and a cavity block and wherein a skin and insert are placed in the mold cavity and foam precursors are poured into the mold cavity to complete the article includes a process in which a series of part replicas are formed and used to cast thermally stable liners that are carried by the mold core and mold cavity. The thermally stable liners have low melt temperatures and can be reused and recast following wear during the molding process. The liners are made from material which has low shrinkage and expansion rates to define a mold assembly that will produce repeatable parts.

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Strafford, NH, United States of America

Kent L Parker