Closure for vehicle trim
This is a continuation of U.S. Pat. No. 604,746 filed Oct. 26, 1990, now abandoned. 
    
    
     TECHNICAL FIELD 
     The present application is concerned with a closure for vehicle trim employing compositions of polypropylene type materials and thermoplastic elastomers. 
     BACKGROUND ART 
     The development of air bags for use in vehicle applications has been an important safety consideration. Occupant restraint systems have been disclosed in U.S. Pat. Nos. 3,904,222 and 3,887,214. These restraint systems are incorporated into the instrument panel structure. The air bag or inflatable occupant restraint cushion is generally retained in a recessed compartment in the instrument panel. 
     Closures for instrument panels are disclosed in U.S. Pat. Nos. 4,893,833 and 4,842,299. Each of these patents require many attachments to the instrument panel or have portions of the closure which may fly about the interior compartment of a vehicle during deployment. The use of an appropriately designed closure leads to a need for soft plastic materials that can be readily produced in high volume. 
     Thermoplastic elastomer blends containing ethylene-propylene thermoplastic block copolymer elastomers as is described in U.S. Pat. No. 4,672,091. Thermoplastic blends of copolymer rubber and polyolefin plastic are described in U.S. Pat. No. 3,835,201. of polyolefin plastics with elastomeric plasticizes are described in U.S. Pat. No. 4,774,277. Polypropylene compositions blended with styrene-ethyl-ene-butylene-styrene block copolymers are described in U.S. Pat. No. 4,871,805. 
     None of the prior art documents disclose a closure for an occupant restraint system that is comprised of a plurality of molded plastic layers comprised of a mixture of polypropylene and thermoplastic elastomers which layers are of differing Shore hardness and wherein one of the layers has a frangible breaking area which facilitates the opening of the closure by rapid expansion of the inflatable restraint cushion upon deployment. 
     SUMMARY OF THE INVENTION 
     Disclosed is a closure capable of opening by expansion of an occupant restraint cushion in a recessed area of an interior vehicle trim comprising: 
     a first molded layer comprised of a mixture of a polypropylene composition and a thermoplastic composition; 
     a second layer integrally molded with and on one side of the first layer covering the recess for the restraint cushion and comprised of a mixture of a polypropylene composition and a thermoplastic elastomer; 
     wherein the first layer has a frangible area on the opposite side of the second layer which area breaks upon exit of the restraint cushion within the closure; and 
     wherein the second layer has a Shore A hardness and is softer than the first layer and is capable of breaking upon exiting of the restraint cushion in a breaking area near the frangible area of the first layer. 
     The invention is also concerned with the method of manufacturing the closure by integrally molding the plastic layers such as by an injection molding technique. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a view of an instrument panel with the closure of the present invention in a closed condition; 
     FIG. 2 is the instrument panel of FIG. 1 with the occupant restraint cushion closure door opened or deployed; and 
     FIG. 3 is a side view of the closure door of the present invention. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     The closure door of the present invention is generally used in the instrument panel 10. The closure door 12 is shown in FIG. 1 in the ready or closed state. FIG. 2 shows the door open where the occupant restraint system such as an air bag is in the deployed state. The deployed air bag is not shown in the drawings. Such occupant restraint systems are described in U.S. Pat. Nos. 3,887,214 and 3,904,222 which are hereby incorporated by reference. 
     The closure is preferably an integral portion of the instrument panel 10. Alternatively, the closure can be affixed to the recessed portion of instrument panel as is generally shown in FIG. 3. 
     The air bag or the occupant restraint system is generally shown at 14. The closure door is comprised of multiple layers, the first plastic layer 16 is generally comprised of a polypropylene and a thermoplastic elastomer. The second layer 18 is also comprised of a mixture of a polypropylene and a thermoplastic elastomer. The first layer has a durometer hardness greater than the second layer. 
     The closure goes from the closed state to the open state as shown in FIGS. 1 and 2 by virtue of the first hard plastic layer being deformed or breaking at point 20. Reference numeral 20 shows a frangible reduced thickness area of the first layer. When the occupant restraint cushion is deployed by the rapid expansion of the air bag, the force of the air bag coming out of the recessed area 22 breaks the first hard plastic layer at recessed portion 20. The recessed portion can be molded at a thickness generally about one-half of the thickness of the first layer. When the deployment of the occupant restraint system occurs and the first plastic layer breaks at point 20, likewise the second layer breaks as well in an area generally shown opposite to recessed area at point 24. Because the second layer 18 is softer, namely, a lower durometer hardness than the first layer, the bending and compressing of the second layer occurs relatively easily. 
     The first layer has a stem 26 which is molded in a T-shape where the upper portion 28 goes to the first layer and the bottom portion 30 is molded with a receiving area or a hole (not shown). The bottom portion can be secured to the recessed area by nut 32 which retains the recessed area 34 in place with the door closure. To securely hold the door closure to the recessed compartment, a second locking mechanism, namely, a bolt 36, secures the first layer appendage 38 to the cooperating appendage 40 of the recessed compartment. Other portions of the instrument panel are shown as 10A which is near that portion of the door closure which remains in place upon deployment of the occupant restraint cushion. Instrument panel portion 10B is near that portion of the door closure which opens upon expansion of the air bag. The remainder of the instrument panel 10D is secured to the recessed compartment 34 by securing means 41 which is a nut holding an appendage of the recessed compartment 42 to the instrument panel 10D. 
     FIG. 3 shows that the second soft layer is frictionally secured to the instrument panel 10B at reference numeral 44. It is to be appreciated that a frictional fit is all that is required to have the closure remain in place. The drawing likewise depicts that the appendage 44 is integrally molded such that it extends beyond the first layer at 46. It is to be appreciated that depending upon the design, the first layer may be directly attached to the instrument panel 10D in order to be more secure or give greater strength to the overall door structure. All that is required is that the soft layer at point 44 have sufficient friction which is overcome by the occupant restraint cushion being deployed so that the door closure goes from the closed position to the open position as shown in FIG. 3. 
     As has been described above, the closure is comprised of multiple plastic layers. The first plastic layer 16 is a molded layer prepared by injection molding of a mixture of a polypropylene and a thermoplastic elastomer. This layer performs the function of a substrate for the second softer layer 18. The substrate layer 16 is generally a layer of polypropylene and a thermoplastic elastomer. The durometer hardness of the substrate layer 16 is such that it is harder than the top layer 18. The durometer hardness would be on the Shore D scale preferably ranging from 30 to 100, even more preferably 50 to 90, especially about 80. 
     The soft layer 18 likewise is comprised of a mixture of a polypropylene and a thermoplastic elastomer. The durometer hardness of the soft layer 18 is generally a Shore A hardness, preferably 5 to 60, even more preferably 10-40, especially about 25. 
     The mixture of a polypropylene and a thermoplastic elastomer is generally prepared by blending the polymeric materials with any well known processing oil. The processing oil can be an aliphatic or aromatic hydrocarbon material. The processing oil can vary in compositional amounts from about 25 to 75 percent of the composition to be molded, preferably 25 to 60 and even more preferably about 40 to 60 percent by weight. 
     To assist the final composition in terms of thermal degradation, stability and overall processing, filler and thickeners may be added to the composition. By &#34;filler&#34; is meant a material which reinforces the composition. Some of the commercially available fillers which may be used are the calcium carbonate fillers such as Duramite, a trademark of the Thompson-Weinman Company; a talc, such as Emtal-41, a trademark of the Englehard Company; a clay, such as McNamee Clay, a trademark of the R.T. Vanderbilt Company; a calcium metasilicate, such as Wallastonite NYAD-400, a trademark of Interpace Company; a silicon dioxide, such as Imsil A-10, a trademark of Illinois Minerals, or Gold Bond R, a trademark of Illinois Minerals, or Gold Bond R, a trademark of Tammsco; a sodium-potassium aluminum silicate, such as Minex 7, a trademark of Kraft Chemical Company; a terephthalic acid, such as TA-33, a trademark of Amoco; a ground feldspar, such as LU-330, a trademark of Lawson United; a clay, such as AF-950, a trademark of the Englehard Company; a titanium dioxide, such as TR-900, a trademark of DuPont; an aluminum tri hydrate; a carbon black, such as Raven H-20, a trademark of Columbia Company; and a pyrogenic microsphere processed from fly ash, such as Orbaloid, a trademark of Midwest Filler Products, fiber, glass and the like. The filler may be a fly ash derivative, such as the pyrogenic microspheres provided by Midwest Filler Products Company. 
     The polypropylene material that may be used is preferably a commercially available material such as crystalline polypropylene or isotactic polypropylene, syndiotactic and tritactic polypropylene. The polypropylene may be a homopolymer or a copolymer such as ethylene propylene copolymer or ethylene propylene block copolymers. Polyolefin plastic blends such as polypropylene and polyethylene or polypropylene and minor amounts of an alphaolefin copolymer of 2-16 carbon atoms may be used as is described in U.S. Pat. No. 4,774,277, herein incorporated by reference. 
     The thermoplastic elastomers that may be used are generally a styreneated rubbery composition. Generally, the materials are styrene ethylene propylene polymers or styrene ethylene butylene-styrene block copolymers. Thermoplastic blends of copolymer rubber and polyolefin plastics are described in U.S. Pat. No. 3,835,201, hereby incorporated by reference. Blends of ethylene propylene diene monomer or ethylene propylene monomers are likewise useful. Thermoplastic elastomers containing ethylene propylene thermoplastic block copolymers are taught in U.S. Pat. No. 4,672,091 which is hereby incorporated by reference. 
     U.S. Pat. No. 4,871,805 likewise discloses styrene ethylene butylene styrene block copolymers and ethylene propylene copolymer rubber and is hereinafter incorporated by reference. Preferred styrene ethylene butylene styrene block copolymers are commercially available as Kraton G1650, G1651, G1652, G1657, G1701, G7528 (trademarks of Shell Chemical Company of Houston, TX) and the like. 
     The soft or second layer 18 is comprised of materials preferably as disclosed below. 
     
         ______________________________________                                    
                  Range of Preferred                                      
Ingredients       Materials                                               
                           Materials (wt %)                               
______________________________________                                    
High Molecular Weight*                                                    
                  25-55    30.5%                                          
S--EB--S Block                                                            
Copolymer*                                                                
Polypropylene*     1-20     7.5%                                          
Aliphatic Hydrocarbon*                                                    
                  25-70    56.5%                                          
Processing Oil                                                            
Stabilizers*      0.1-5    1%                                             
Calcium Carbonate*                                                        
                   1-15     4.5%                                          
Total             100%     100%                                           
______________________________________                                    
 *G7528                                                                   
 
    
     The hard substrate material 16 is comprised of the following ingredients: 
     
         ______________________________________                                    
               Range of Preferred                                         
Ingredients    Materials                                                  
                        Materials (wt %)                                  
______________________________________                                    
Polypropylene  50-90    80%                                               
Thermoplastic  10-50    20%                                               
Elastomer                                                                 
Total          100%     100%                                              
______________________________________                                    
 
    
     In some applications, in order to ensure high strength to the closure door, it has been found advantageous to incorporate a reinforcing means in the substrate 16. This could be accomplished by fibers such as glass fibers and the like, glass microballoons, or metallic screens such as aluminum, steel, and the like. Preferably, the screen would be a swiss cheese-type screen where along the line 20 a recessed notch is located, the screen would have a plurality of apertures so that the closure door would fracture along the frangible breaking means. 
     The thickness of substrate 16 ranges from 2.0 to 4.0 mm. The thickness for the soft top layer 18 ranges from 2.0 to 5.0 mm. 
     It has been found advantageous to coat or paint the outer portion of the soft member 18 in order for it to be color coordinated with the remainder of the instrument panel 10. A preferred coating composition is a polyol cross-linked with isocyanate to give a cross-linked polyurethane. The polyols that may be used are low molecular weight polyols or resinous polyols that have a molecular weight up to about 5000. Suitable polyols are di - and polyfunctional hydroxy compounds as hydroxyl terminated polyethers or polyesters and di - or polyisocyanates. Polyols such as trimethylol propane or hexane triol may be utilized. Uralkyds may also be used such as those based on castor oil and castor oil derivatives. The polyols may be diols, triols, tetrols or a combination of same to give the desired NCO/OH ratio. 
     Suitable polyols can also be poly(oxypropylene) glycols and derivatives of same based upon alkylene oxide derivation such as poly(oxypropylene), poly(oxyethylene) glycols, and the like. 
     The polyols are reacted with isocyanates of a wide variety. Suitable isocyanates are as follows: 
     isopherone diisocyanate, 
     propylene-1,2-diisocyanate, 
     butylene-1,3-diisocyanate, 
     butylene-1,2-diisocyanate, 
     hexamethylene diisocyanate, 
     octamethylene diisocyanate, 
     nonamethylene diisocyanate, 
     decamethylene diisocyanate, 
     2,11-diisocyano-dodecane and the like, 
     meta-phenylene diisocyanate, 
     para-phenylene diisocyanate, 
     toluene-2,4-diisocyanate, 
     toluene-2,6-diisocyanate, 
     xylene-2,4-diisocyanate, 
     dialkyl benzene diisocyanate, such as methylpropylbenzene diisocyanate, methylethylbenzene diisocyanate, and the like, 
     2-2&#39;-biphenylene diisocyanate, 
     3,3&#39;-biphenylene diisocyanate, 
     4,4&#39;-biphenylene diisocyanate, 
     3,3&#39;-dimelhyl-4,4&#39;-biphenylene-diisocyanate, and the like, 
     methylene-bis-(4-phenyl isocyanate), 
     ethylene-bis-(4-phenyl isocyanate), 
     isopropylidene-bis-(4-phenyl isocyanate), 
     butylene-bis-(4-phenyl isocyanate), 
     hexafluoroisopropylidene-bis-(4-phenyl isocyanate), and the like, 
     2,2&#39;-oxidiphenyl diisocyanate, 
     3,3&#39;-oxidiphenyl diisocyanate, 
     4,4&#39;-oxidiphenyl diisocyanate, and the like, 
     2,2&#39;-ketodiphenyl diisocyanate, 
     3,3&#39;-ketodiphenyl diisocyanate, 
     4,4&#39;-ketodiphenyl diisocyanate, 
     2,2&#39;-thiodiphenyl diisocyanate, 
     3,3&#39;-thiodiphenyl diisocyanate, 
     4,4&#39;-thiodiphenyl diisocyanate, and the like, 
     2,2&#39;-sulfonediphenyl diisocyanate, 
     3,3&#39;-sulfonediphenyl diisocyanate, 
     4,4&#39;-sulfonediphenyl diisocyanate, and the like, 
     2,2&#39;-methylene-bis-(cyclohexyl isocyanate), 
     3,3&#39;-methylene-bis-(cyclohexyl isocyanate), 
     4,4&#39;-methylene-bis-(cyclohexyl isocyanate), 
     4,4&#39;-ethylene-bis-(cyclohexyl isocyanate), 
     4,4&#39;-propylene-bis-(cyclohexyl isocyanate), 
     bis-(para-isocyano-cyclohexyl) sulfide, 
     bis-(para-isocyano-cyclohexyl) sulfone, 
     bis-(para-isocyano-cyclohexyl) ether, 
     bis-(para-isocyano-cyclohexyl) diethyl silane, 
     bis-(para-isocyano-cyclohexyl) diphenyl silane, 
     bis-(para-isocyano-cyclohexyl) ethyl phosphine oxide, 
     bis-(para-isocyano-cyclohexyl) phenyl phosphine oxide, 
     bis-(para-isocyano-cyclohexyl) N-phenyl amine, 
     bis-(para-isocyano-cyclohexyl) N-methyl amine, 
     2,6-diisocyano-pyridine, 
     bis-(4-isocyano-phenyl) diethyl silane, 
     bis-(4-isocyano-phenyl) diphenyl silane, 
     dichloro-byphenylene diisocyanate, bis-(4-isocyano-phenyl) ethyl phosphine oxide, 
     bis-(4-isocyano-phenyl) phenyl phosphine oxide, 
     bis-(4-isocyano-phenyl)-N-phenyl amine, 
     bis-(4-isocyano-phenyl)-N-methyl amine, 
     3,3&#39;-dimethyl-4,4&#39;-diisocyano biphenyl, 
     3,3&#39;-dimethoxy-biphenylene diisocyanate, 
     2,4-bis-(β-isocyano-t-butyl) toluene, 
     bis-(para-β-isocyano-t-butyl-phenyl) ether, 
     para-bis-(2-methyl-4-isocyano-phenyl) benzene, 
     3,3&#39;-diisocyano adamantane, 
     3,3&#39;-diisocyano biadamantane, 
     3,3&#34;-diisocyanoethyl-1,1&#39;-biadamantane, 
     1,2bis-(3-isocyano-propoxy) ethane, 
     1,2-dimethyl propylene diisocyanate, 
     3-methoxy-hexamethylene diisooyanate, 
     2,5-dimethyl heptamethylene diisocyanate, 
     5-methyl-nonamethylene diisocyanate, 
     1,4-diisocyano-cyclohexane, 
     1,2-diisocyano-octadecane, 
     2,5-diisocyano-1,3,4-oxidiazole, 
     OCH(CH 2 ) 3  O(CH 2 ) 2  O(CH 2 ) 3  NCO, 
     OCH(CH 2 ) 3  S(CH 2 ) 3  NCO, 
     OCH(CH 2 ) 3  N(CH 2 ) 3  NCO, 
     polymethylene polyphenyl isocyanate. 
     Biurets such as the biuret of hexamethylene diisocyanate and uretdiones may be used. The latter are obtained by the oligomerization of hexamethylene diisocyanate in the presence of suitable catalysts such as tributylphosphene and the like. 
     A number of blocking agents may also be used to produce a blocked isocyanate which could be used as the cross-linking agent. Such blocking agents will unblock at about 50° C. to make the isocyanate available. Such blocking agents are the phenol type, lactone type, active methylene type, alcohol type, mercaptan type, acid amide type, the imide, the amine type, the urea type, carbamate type, oxime type, sulfate type and the like. Most preferably a ketoxime type is preferred, and even more preferably a dialkyl ketoxime of from 1 to 4 carbon atoms per alkyl group. Most preferably, the ketoxime would be methylethyl ketoxime, methyl-isobutyl ketoxime, and the like. 
     Other inert materials may be added such as pigments for coloration, ultraviolet absorbers and antioxidants such as benzophenone derivatives and substituted benzotriazoles. Flow control agents may be added to enhance leveling and to avoid cratering and bubbling in the urethane coatings. Drying agents are also added to increase the viscosity of the urethane coating, to help eliminate bubbling and high solids content and to control sagging when the coatings are applied on vertical substrates. Suitable materials are cellulose acetate butyate or polyvinyl butyral. Because urethane coatings may exhibit a high gloss, flattening agents may be added to reduce the gloss. Suitable flattening agents are finely divided silicas, diatomaceous earth, certain metal stearates such as aluminum and zinc stearate, and the like. 
     While thermoplastic urethane coatings can be utilized, it is preferred that two component systems be used, namely, that the isocyanate be separate from the polyol until shortly before application. With a two component thermoset system, catalysts are generally used such as tin catalysts, amine catalysts and the like. 0n occasion, it has been found desirable to use amino formaldehyde as the curing agent such as an alkyl ether (methyl or butyl ether) of a methylol melamine or methylol urea derivative (melamine-urea formaldehyde condensation products or derivatives). Suitable urethane coating systems are disclosed in APPLIED POLYMER SCIENCE, by J. Kenneth Craver and Roy W. Tess, published by the American Chemical Society, 1975, pages 829-858, hereby incorporated by reference. 
     Having described the invention in general, listed below are embodiments wherein all parts are in parts by weight and all temperatures are in degrees Centigrade, unless otherwise indicated. 
     EXAMPLE 
     Step One -- Preparing The Substrate 
     The substrate material is made by using a Unidyn Megacolor (trademark of Universal Dynamics Corp. of Woodbridge, VA) pelletized material mixer to blend a batch of 80 percent by weight glass reinforced polypropylene copolymer (SB224-2 (trademark of Himont Corporation of Troy, MI)) with 20 percent impact modifier (50% by weight of low density polyethylene and 50% by weight of Shell G1651). Table 1 shows the physical data of the mixed material. 
     A metal reinforcement is made by using a SAE-1008 steel sheet cut to a specific designed shape including off-set perforated holes along the flangible area. 
     Drying of the mixed material occurs using a Unidyn Model DHD-6 dryer at 180° F. for 4 hours. The mold is set in a HPM (Corporation of Mt. Gilead, OH) 500 ton injection molding machine with a 48 ounce injection unit. 
     The air bag door substrate is made by inserting the metal reinforcement into the cavity of the mold and injection molding over it and completely enclosing it within the plastic. Table 2 is the molding parameters. 
     Step Two -- Molding Soft Cover 
     Table 3 shows the performance data of the soft cover material (Shell Kraton(R) G7528). It was dryed at 180° F. for two hours prior to molding. The mold was set in a HPM 500 ton injection molding machine with a 48 oz. injection unit. The part was finished by inserting the substrate from Step 1 into the cavity and injecting molding the Shell material G7528 overlay. Table 4 lists the molding parameters. 
     Step Three -- Painting 
     The molded air bag door was washed in a soap and water solution and blown dry prior to decoration. The surface finish is accomplished by spraying a Dexter chlorinated hydrocarbon primer and a two-component polyurethane color paint over the molded air bag door soft cover. Parts were painted using Bink&#39;s air atomized spray equipment. Table 5 and Table 6 are the specifications of the primer and the coating respectively. The washing and painting were conducted at ambient temperature. The painted parts were then flashed at 80° F. for 15 minutes and baked at 175° F. in an oven. 
     
                       TABLE 1                                                     
______________________________________                                    
PHYSICAL PROPERTIES OF MIXTURE                                            
OF POLYPROPYLENE &amp; SHELL KRATON                                           
G1651 AND POLYETHYLENE                                                    
Physicals                                                                 
______________________________________                                    
SPEC. GRAVITY            1.00                                             
MELT FLOW (ASTM D1238 (0.1 g/min)                                         
                         3.20                                             
INTRINSIC MELT VISCOSITY (poise) 446 F.                                   
                         560                                              
245 lb., 25:1 L/D                                                         
TENSILE STRENGTH, psi (ASTM D638)                                         
(Type I, 2&#34;/min)                                                          
@ yield                  6070                                             
@ break                  6060                                             
ELONGATION, % (ASTM D638)                                                 
@ yield                  6.00                                             
@ break                  6.40                                             
FLEXURAL MODULUS, psi (ASTM D790B)                                        
1/2&#34; × 1/8&#34; × 5&#34;, 0.05&#34;/min.                                  
Secant (0.1&#34; deflect)    242,600                                          
Tagent                   306,400                                          
FLEXURAL STRENGTH, psi (ASTM D790B)                                       
                          8,260                                           
HEAT DEFLECTOR TEMP (C.) 66/264 psi                                       
                         153/103                                          
(ASTM D648)                                                               
HARDNESS (Shore D)       83                                               
TOOL SHRINK (mils/in)    4.3                                              
AFTERBAKE (mils/in)      5.1                                              
1 hr. @ 250 F.                                                            
DYNATUP IMPACT, Room Temperature                                          
(23° C.)                                                           
(5 mph, 3&#34; Backup, 1&#34; Dart)                                               
Ultimate Energy, (Jules) 4.1                                              
Total Energy, (Jules)    12.45                                            
Ultimate Force, (Neutron)                                                 
                         1,280                                            
Sample Thickness, inches 0.121                                            
______________________________________                                    
 
    
     
                                           TABLE 2                                 
__________________________________________________________________________
SUBSTRATE PROCESSING PARAMETERS                                           
__________________________________________________________________________
Clamp Control                                                             
                        Position                                          
                               Speed Pressure                             
                                           Time                           
                        Units  Sec.  psi.  (Sec.)                         
__________________________________________________________________________
 ##STR1##               13.25  .02  1.50 6.00 2.00 4.50                   
                                35 40 11 15 25 15                         
                                      1500 1500 2000 2000  450 2000 1500  
                                     1500   21.00 10                      
__________________________________________________________________________
Temperature Control                                                       
         HEAT: ON          ALARM LIMIT +/- : 20                           
         Zone                                                             
            Set                  Actual                                   
__________________________________________________________________________
         # 1                                                              
            480                                                           
         # 2                                                              
            430                                                           
         # 3                                                              
            430                                                           
         # 4                                                              
            420                                                           
__________________________________________________________________________
Microprocessor Injector Control                                           
                                          SYSTEM                          
                                  RAM                                     
                                       INJ.                               
                                           PRESS                          
                                 POSN.                                    
                                     SPEED                                
                                            (psi)                         
__________________________________________________________________________
 ##STR2##                              .90.80.80.60.60.50.50.50.40.4035.00
                                     2     2000 21002100210021002100210021
                                          00210021002100                  
__________________________________________________________________________
Pressure Control                                                          
                Pack.                                                     
Hold Pressures  Press              Back Pressures                         
__________________________________________________________________________
Hold Time  :  25.0      Plast. Delay                                      
                                   :                                      
Press. Steps                                                              
           :  1         Press. Steps                                      
                                     : 1                                  
Step #1    : 450        Step #1      : 50                                 
                        PURGE PRESSURE                                    
                                      : 900                               
__________________________________________________________________________
Process Control                                                           
                             SET POINT                                    
                                    ACTUAL                                
__________________________________________________________________________
AUTOMATIC SHOT CORRECTION :  OFF                                          
  Shot Size               :  5.25 unit                                    
AUTO FEED                 :                                               
BOOST CUTOFF ON RAM POSITION                                              
  Cutoff Distance         :   .50 unit                                    
  Cushion                 :                                               
__________________________________________________________________________
Auxiliary Equipment                                                       
       MOLD AND DRYER TEMPERATURES                                        
       CAVITY : 125° F.                                            
                             DRYER :                                      
       CORE : 125° F.                                              
       LIFTER :                                                           
       PUMPS:                                                             
       EXTRUDER PUMPS : 1                                                 
       INJECTION PUMPS : 1                                                
       BOOSTER POSITION : OFF                                             
       EJECTOR RETRACT       EJECTOR FORWARD                              
       POSITION                                                           
              .50 Units      POSITION                                     
                                    1.75                                  
       SPEED  40             SPEED  40                                    
       PRESSURE                                                           
              40             PRESSURE                                     
                                    40                                    
       EJECTOR / CORE  START POSITION  10.00 UNIT                         
__________________________________________________________________________
 
    
     
                       TABLE 3                                                     
______________________________________                                    
SHELL G7528 PHYSICAL PROPERTIES (1)                                       
Physicals                                                                 
______________________________________                                    
SPEC. GRAVITY           0.91                                              
SHORE A HARDNESS, inst/10 sec                                             
                        25/23                                             
TEST METHOD ASTM D2240                                                    
TENSILE PROPERTIES, par (2)                                               
TEST METHOD ASTM D412                                                     
Tensile strength, MPa (psi)                                               
                        5.8     (840)                                     
100% Modulus, MPa (psi) 0.6     (84)                                      
300% Modulus, MPa (psi) 1.8     (264)                                     
500% Modulus, MPa (psi) 4.0     (581)                                     
Ultimate Elongation, %          640                                       
TENSILE PROPERTIES, perp (2)                                              
TEST METHOD ASTM D412                                                     
Tensile strength, MPa (psi)                                               
                        &gt;8.8    (1280)*                                   
100% Modulus, MPa (psi) 0.4     (62)                                      
300% Modulus, MPa (psi) 1.0     (140)                                     
500% Modulus, MPa (psi) 2.1     (303)                                     
Ultimate Elongation, %          &gt;950*                                     
TEAR STRENGTH, Die C                                                      
TEST METHOD ASTM D624                                                     
parallel, kN/m (pli)    10.1    (58)                                      
perpendicular, kN/m (pli)                                                 
                        22.0    (126)                                     
WATER ABSORPTION, % wt (3)      &lt;0.1                                      
TEST METHOD ASTM D570-6.1                                                 
______________________________________                                    
 (1) Determined on laboratoryprepared injection molded 130 × 150    
 × 3.2 mm plaques.                                                  
 (2) &#34;par&#34;, parallel, machine direction, mold flow direction &#34;perp&#34;,      
 perpendicular or transverse to machine direction.                        
 (3) Test specimens 1/8&#34; thick, 2.1&#34; diameter discs                       
 *Sample did not break within the travel of the (INSTRON) testing equipmen
 
    
     
                                           TABLE 4                                 
__________________________________________________________________________
PROCESSING PARAMETERS OF SHELL KRATON G7528                               
__________________________________________________________________________
Clamp Control                                                             
                        Position                                          
                               Speed Pressure                             
                                           Time                           
                        Units  Sec.  psi.  (Sec.)                         
__________________________________________________________________________
 ##STR3##               18.00  .02  1.50 6.50 4.00 4.00                   
                                25 30 12 20 30 25                         
                                      1500 2500  600 2100  400 2100 2100  
                                     1500   25.0 10.0                     
__________________________________________________________________________
Temperature Control                                                       
         HEAT: ON          ALARM LIMIT +/- : 20                           
         Zone                                                             
             Set                 Actual                                   
__________________________________________________________________________
         # 1                                                              
            450                                                           
         # 2                                                              
            440                                                           
         # 3                                                              
            430                                                           
         # 4                                                              
            400                                                           
__________________________________________________________________________
Microprocessor Injector Control                                           
                                          SYSTEM                          
                                  RAM                                     
                                       INJ.                               
                                           PRESS                          
                                 POSN.                                    
                                     SPEED                                
                                            (psi)                         
__________________________________________________________________________
 ##STR4##                              2.002.002.002.002.001.501.501.00   
                                     .90 .5060.00                         
                                           2100 21002100210021002100210021
                                          00210021002100                  
__________________________________________________________________________
Pressure Control                                                          
                Pack.                                                     
Hold Pressures  Press              Back Pressures                         
__________________________________________________________________________
Hold Time  :  10.00     Plast. Delay                                      
                                   :                                      
Press. Steps                                                              
           :  1         Press. Steps                                      
                                     : 1                                  
Step #1    : 100        Step #1      : 50                                 
                        PURGE PRESSURE                                    
                                      : 900                               
__________________________________________________________________________
Process Control                                                           
                             SET POINT                                    
                                    ACTUAL                                
__________________________________________________________________________
AUTOMATIC SHOT CORRECTION :  OFF                                          
  Shot Size               :  3.25 unit                                    
BOOST CUTOFF ON RAM POSITION                                              
  Cutoff Distance         :   .50 unit                                    
  Cushion                 :                                               
__________________________________________________________________________
Auxiliary Equipment                                                       
        MOLD AND DRYER TEMPERATURES                                       
        CAVITY : 125° F.                                           
                            DRYER : Off                                   
        CORE : 125° F.                                             
        LIFTER :                                                          
        PUMPS:                                                            
        EXTRUDER PUMPS : 1                                                
        INJECTION PUMPS : 1                                               
        BOOSTER POSITION :                                                
        EJECTOR RETRACT     EJECTOR FORWARD                               
        POSITION                                                          
               2.50         POSITION                                      
                                   3.00                                   
        SPEED  60           SPEED  50                                     
        PRESSURE                                                          
               60           PRESSURE                                      
                                   50                                     
        EJECTOR / CORE START POSITION 12.00                               
        COMMENTS:                                                         
          Fill Speed = 2.40 sec.                                          
__________________________________________________________________________
 
    
     
                       TABLE 5                                                     
______________________________________                                    
DEXTER COATING SPECIFICATIONS                                             
______________________________________                                    
Product Data Sheet                                                        
Product Identification                                                    
             Dextrasoft Very Dark Sapphire                                
             PD070106                                                     
Physical Constants                                                        
Type         Polyested Polyol (m w.sub.m 100-6500)                        
Solids (By Weight)                                                        
             Unmixed-56.3 ± 2% Mixed-54.87 ± 2.0%                   
Solids (By Volume)                                                        
             Unmixed-46.9 ± 2% Mixed-45.2 ± 2.0%                    
V.O.C. Level Mixed 4.0 lb/gal.                                            
Coverage     725 Mixed                                                    
(Sq. Ft./Gal. Dry                                                         
Mil)                                                                      
Weight/Gallon                                                             
             8.9 ± 0.2 lb.                                             
Viscosity at 77° F.                                                
             17-20&#34; No. 3 Zahn (mixed) @                                  
Gloss        60° F. Gardner 2-3 on a smooth                        
             surface                                                      
Application                                                               
Mixing Instructions                                                       
             Mix 4 volumes PD070106                                       
             with 1 volume PD070097.                                      
             mix thoroughly                                               
______________________________________                                    
 
    
     
                       TABLE 6                                                     
______________________________________                                    
DEXTER COATING SPECIFICATIONS                                             
______________________________________                                    
Product Data Sheet                                                        
Product Identification                                                    
               Clear Dextrasoft Activator                                 
               PD070097                                                   
Physical Constants                                                        
Type           Isocyanate [Blend of TDI (toluene                          
               diisocyanate) and HDI (Saturated                           
               methylene diisocyanate) biuret]                            
Solids (By Weight)                                                        
               45.6 ± 2.0%                                             
Solids (By Volume)                                                        
               38.2 ± 2.0%                                             
Coverage                                                                  
Weight/Gallon  8.43 ± 0.2 lbs.                                         
Viscosity at 77° F.                                                
               Activator before mixing with                               
               Dextrasoft Bases Nos. 2 Zahn                               
               16&#34;-19&#34;                                                    
______________________________________                                    
 
    
     While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. It is not intended herein to mention all of the possible equivalent forms or ramifications of the invention. It is understood that the terms used herein are merely descriptive rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention.