Abstract: An energy dissipation assembly is provided for dissipating energy between a vehicle component and a vehicle sheet metal member. The assembly includes a collapsible crash box forming a central aperture therethrough for receiving the vehicle component. The collapsible crash box includes a plurality of collapsible levels oriented concentrically with respect to the central aperture. A sufficient impact against the component causes collapse of the plurality of levels between the component and the sheet metal member, thereby dissipating energy of the impact.

Abstract: A sun visor is disclosed having a body with an aperture through which an extender blade selectively slides between fully retracted and fully extended positions. The visor body is a clamshell type having first and second shell halves. A guide rib is located on one shell half to align and guide the extender blade as it moves into and out of the visor body. The aperture is formed by a recessed portion in at least one of the shell halves. Fabric covers the visor body and also extends into the aperture and covers at least part of the guide rib.

Abstract: A console and method of installing a console for a motor vehicle or the like including a passenger cabin. The console includes an accessory module for use by occupants of the vehicle and has a housing with fasteners adapted to mount the console within the vehicle cabin. A chamber having an open side is formed in the console and receives an accessory module. At least a portion of the housing comprises an expanded polymeric material, preferably expended polypropylene, to provide a soft surface within the vehicle cabin.

Abstract: A method of making a headliner assembly includes providing a porous member having first and second sides. A negative pressure is developed on the second side of the porous member, and particulate material is selectively deposited proximate the first side of the porous member to form a particulate layer having an outline that corresponds with a desired outline of the headliner assembly. The particulate material is drawn toward the first side of the porous member by the negative pressure developed on the second side of the porous member. The particulate layer is then thermoformed to form the headliner assembly.

Abstract: A vehicle overhead console assembly includes a console body with a door pivotally attached to the console body. The door is pivotally movable between open and closed positions. A navigation display unit is connected to the door such that the navigation display unit is exposed for viewing by a vehicle occupant when the door is in the open position, and hidden from view when the door is in the closed position.

Abstract: A headliner for motor vehicles includes first and second sheets of material in juxtaposition to each other and adapted for positioning in a mold having two mold portions. The material of at least one of the sheets is fluid deformable with respect to another of the sheets, and is attachable to the material of the other of the sheets by the mold portions at sufficient locations to outline a potential duct between the sheets. The potential duct is adapted to receive fluid between the sheets for forming an actual duct. When fluid is received between the sheets, the material of the at least one sheet is deformed with respect to the material of the other of the sheets to define the actual duct. In one embodiment of the headliner, at least one head impact block is disposed in the duct. The headliner may also include at least one substantially air-impermeable layer disposed within the duct and attached to at least one of the the first and second sheets. Furthermore, the layer preferably includes a polymer powder.

Abstract: A grab handle assembly for attaching a grab handle to a vehicle roof. The grab handle assembly comprises a mounting clip having a fastener that passes through the aligned openings in the headliner and a vehicle roof bracket to secure the mounting clip to the vehicle roof and to additionally mount the headliner to the vehicle roof. The mounting clip further includes a lug extending downwardly from a lower surface of the mounting clip. The grab handle has opposing ends that terminate in a planar tab with an opening, which is sized to receive the lug. To connect the mounting clip and the grab handle, the lug is inserted through the opening in the grab handle and the mounting clip and grab handle are rotated relative to each other approximately 90.degree. to connect the grab handle and the mounting clip.

Abstract: An overhead console for a vehicle or the like includes a housing defining a transmitter storage compartment for a garage door opener and an opening for permitting access to the storage compartment. A door is pivotally mounted to the housing for movement between a closed position for covering the opening and an open position for exposing the interior of the compartment through the lower opening. A hinge assembly for pivotally mounting the door to the housing includes a pair of spaced cams integrally molded to the door and a pair of spaced spring arms integrally molded to the housing. The spring arms are engageable with the cams as the door moves toward the open position from the closed position to arrest the movement of the door at an intermediate position between the closed and open positions. The spring arms are engageable and deflectable by the cam to provide frictional resistance to movement of the door only from the intermediate position to the open position.

Abstract: A passenger assist handle for use in an automobile includes a handle pivotably mounted to a base and biased in an non-use position by a helical torsion spring. The base has an upstanding mounting block for pivotably retaining the handle and a mounting clip for mounting the base to an automobile frame. The handle has first and second ends each of which is pivotably mounted to the base through a pin which extends through openings in each end of the handle and through the base pivot mounts for movement between first and second positions with respect to the base. The spring has a first end extending into and anchored in the spring hole in the base. The spring is further coiled around the pin between the pivot mounts and has a second end distal from the first end which is anchored in the first end of the handle. The handle further includes a ledge for retaining the second end of the spring in the handle.

Abstract: A vehicle sun visor according to the invention includes a frame defining an open-top channel and a track assembly mounted to the frame in the channel. The track assembly includes a planar central portion and depending parallel sidewalls. Each track sidewall is hinged to the central portion for hinged articulation of the sidewalls relative the central portion prior to assembly within the frame. Further, each track sidewall has at least one inwardly directed flange forming at least one track. An extender blade is mounted in the at least one track for sliding movement from a retracted position substantially within the track assembly to an extended position wherein the extender blade at least partially extends from the track assembly.

Abstract: An overhead console for a vehicle has a support structure (14) with walls (30, 80, 82, 84) and an access door (10) defining a compartment (78) for storing a remote transmitter (86). The transmitter (86) includes an actuator switch (92) that is normally manipulated by a user for operating the transmitter (86) to open a garage door, turn on lights, etc., from inside the vehicle. The console access door (10) is attached to the support structure (14) for movement between closed and open positions. A manually operable actuator (12) is engageable with the transmitter switch (92) for operating the transmitter (86) upon depression of the actuator (12). The actuator (12) is attached to the support structure (14) independent of the door (10) such that movement of the actuator (12) is at least substantially unaffected by movement of the door (10) between the closed and open positions.

Abstract: A sun visor assembly is adapted for attachment in a vehicle having a front windshield and a side door window. The sun visor assembly includes a slide track attachable to the vehicle above the side door window. A slide bracket is slidably disposed within the channel. A sun visor pivotably cooperates with the slide bracket, and is pivotable about an axis. An automatic pivot assembly is operatively connected between the slide track and the sun visor for automatically pivoting the sun visor toward a position in which the sun visor is substantially parallel with the slide track as the slide bracket is moved in a direction away from the front windshield, thereby preventing interference of the sun visor with a vehicle occupant as the sun visor is moved between the front windshield and side door window.