Huron Plastics Group, Inc.

Trw Vehicle Safety Systems Inc.

Blue Water Plastics, Inc.

Sarnamotive Blue Water, Inc.

Richard J Barton

Jaime L Klomhaus

Jack A Phillion

Scott M Bell

Jamie L Klomhaus

Brian L Martin

Darlene E Forster

Robert M Gallagher

Gary M Meyers

A flap-type pressure relief valve for venting of pressure out of, for example, an automobile passenger compartment has a flap assembly manufactured by a co-molding operation and inserted into a valve housing to block the flow of air therethrough. The valve flap assembly includes a flap carrier frame formed from a relatively rigid plastic in the first shot of a two-shot co-molding process, and at least one flap formed from a relatively flexible plastic in the second shot. The co-molding joins the flap to a first perimeter wall of the frame along an edge of the flap, and the flap is sufficiently flexible to bend about a line adjacent the edge. In a two flap version, a second flap co-molded into connection with a second perimeter wall of the frame. The resulting flap assembly can be easily connected with the separately-molded valve housing by securing the frame to the housing such that the flaps are positioned over valve seat within the housing. The flaps are co-molded into connection with the frame such that when the frame is secured to the housing to position the flaps over the air passages, the flaps are bent away from the as-molded configurations, thereby generating elastic force urging the flaps toward the respective valve seats. The flaps can have rigid plastic stiffeners co-molded into connection therewith. The stiffeners are preferably formed simultaneously with the frame in the first shot of the co-molding process.

Pressure relief valve and method of manufacturing the same

A pressure relief valve such as is used to relieve over-pressure in the passenger compartment of an automotive vehicle has valve flaps which are retained in connection with a housing by molded-in-place retainer strips. The valve is manufactured by an injection molding tool having a pair of mold halves defining a first mold cavity for forming the housing and a second mold cavity for forming the flaps. After the housing and flaps have set, the mold is opened, with the housing remaining in contact with one mold half and the flaps remaining in contact with the other mold half. One mold half is then moved relative to the other to place the housing and the flaps in alignment with one another, and the mold halves are closed again to place the flaps inside the housing and define a third mold cavity extending along the lines of desired attachment between the flaps and the valve seats. A third quantity of thermoplastic material is injected into the third mold cavity where it sets to form the retainer strips, bonding with the edges of the flap and the adjacent edges of the valve seat. The third mold cavity also extends around a peripheral flange surrounding the housing, forming a seal which is bonded to the housing. The part is complete when ejected from the mold, with no additional assembly required.

A plastic molded part having a parting line free O-ring groove formed on a tubular portion of the part is made by molding the groove utilizing cooperating inner and outer axially moveable die portions in which an inner die member is withdrawn from the tubular plastic just before the outer die member is withdrawn, with the withdrawal of the members occurring after the plastic has begun to set but before it has assumed its final cure, whereby the plastic may flex inwardly as the outer die is withdrawn and then may spring back outwardly to its proper position for final cure.

Method of making plastic part having parting line free O-ring groove for

A deployment door assembly (28) covers an inflatable air bag (12) contained in a reaction canister (24) mounted in a vehicle (16). The deployment door assembly (28) includes first and second continuous pieces of plastic material. The first piece defines a substrate (50) having a panel portion (56), first wall portions (170-174), and second wall portions (180-188). The panel portion (56) closes an opening (49) in the vehicle (16), and defines boundaries of a deployment door (32). The first wall portions (170-174) extend across the deployment door (32), and project inward from the deployment door (32). The second wall portions (180-188) surround the deployment door (32), and direct the inflating air bag (12) to move outward from the reaction canister (24) toward and against the first wall portions (170-174). The second continuous piece of plastic material defines an outer layer (52) which covers the substrate (50) in overlying surface contact. An outer side surface (72) of the outer layer (52) continues the trim theme of the vehicle (16) across and around the deployment door (32).

Deployment door assembly

A one-way air valve for relieving pressure within the passenger compartment of an automobile includes a plastic frame having an air passage therethrough with a flap integrally molded with the frame but of more elastic material and connected to the frame by a living hinge. The flap is molded in a position extending through the passageway and the living hinge is spring loaded by swinging the flap back through the passageway to overlie the outside of the frame over the passageway, thereby biasing the flap against the frame.

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Port Huron, MI, United States of America

Richard J Barton