Abstract: A method for manufacturing a vehicular door assembly (10) having a door (12), a door panel (14), a substrate (54), a plurality of systems, and a plurality of components. The method includes the steps of fastening the door panel (14) to the door (12), attaching the substrate (54) to the door panel (14), and securing the plurality of components to the substrate prior to attaching the substrate to the door panel (14) such that each of the plurality of components is operational upon the substrate being attached to the door panel (14).

Abstract: A vehicular module (20) secures a plurality of components to a motor vehicle (10) having a frame (29). The vehicular module (20) includes a tray (22) and a support member (24) that is fixedly secured to the tray (22). The tray (22) includes a plurality of receiving apertures for mounting a plurality of components thereto. The support member (24) engages the frame (29) of the motor vehicle (10) to support the tray (22) and provide structural integrity to the vehicle frame (29). The module (20) may be pre-assembled prior to installation to the vehicle frame (29).

Abstract: A control valve is provided which may be incorporated within a fluid operating system. The valve has an internally-mounted check element which allows the valve to provide a fail-safe mode for a downstream device in fluid communication with the control valve. The invention includes the control valve, the valve in combination with a downstream device, and a method whereby the flow of pressurized fluid is controlled by operation of the control valve.

Abstract: A method for supporting an electrical component in a vehicle includes providing an electrical component, selecting a vehicle component to be made at least in part of a flexible foam material, and producing the vehicle component such that the electrical component is embedded in the foam material of the vehicle component, thereby providing support for the electrical component.

Abstract: A method for supporting an electrical component in a vehicle includes providing an electrical component, selecting a vehicle component to be made at least in part of a flexible foam material, and producing the vehicle component such that the electrical component is embedded in the foam material of the vehicle component, thereby providing support for the electrical component.

Abstract: A method of manufacturing a vehicle pull handle assembly includes injection molding a pull strap portion in the first shot of a multi-shot molding process. The pull strap portion includes a first pivot joint member. A base is over-molded onto the pull strap portion in the second shot of the multi-shot molding process. The base includes a second pivot joint member which pivotally mates with the first pivot joint member but does not chemically bond with the first pivot joint member in the final molded pull handle assembly.

Abstract: An attachment connection (18) for securing a vehicle trim component (16) to a vehicle body sheet metal panel (20) includes an attachment projection (22) extending from the trim component with an attachment formation (24) molded in situ thereon from a softer material. An opening (26) in the sheet metal panel (20) includes a cantilevered leaf spring (28) having a terminal end (30) that is engaged with the softer attachment formation (24) upon insertion of the attachment projection into the opening to thereby provide securement of the trim component. The leaf spring (28) has a curved section (32) to provide enhanced spring action thereof and its terminal end (30) preferably has a curved shape that engages the attachment formation (24) on the attachment projection (22).

Abstract: An instrument panel top cover is provided with an integrally molded foam underside. The integrally molded foam underside provides a number of components that have been supplied separately in the prior art. The use of the integrally molded foam underside thus eliminates the need for many separate components and improves upon the instrument panel top covers of the prior art.

Abstract: A trim panel includes a plurality of ribs projecting from a surface of the trim panel. Fluent, conductive material is sprayed onto the ribs at an angle such that distinct electrical traces are formed on each rib. The gauge of each electrical trace can be determined by varying the height of each rib. The gauge of each electrical trace can also be determined by varying the angle of the rib relative to the surface of the trim panel.

Abstract: An improved cross car beam is tailored to be utilized in either right hand or left hand drive applications. The cross car beam has channels which extend for elongate distances such that components mounted to the cross car beam can be mounted in the channels at an infinite number of locations. This allows the use of a single cross car beam for both right hand and left hand drive applications.

Abstract: A wire harness generally comprises a plurality of wires encased by a continuous, molded sheath. The wire harness generally includes a main trunk from which a plurality of branches extend. The sheath is formed continuously over the main trunk and branches. In one embodiment, the wire harness has an undeformed shape which substantially matches a surface of a component to which the wire harness is mounted.

Abstract: Injection molding techniques are utilized to form complex switches without removal from a molding machine. Multi-shot molding techniques are utilized, as are rotational indexing molding machines. Springs are formed of resilient elastomeric material. Contacts may be inserted into the mold prior to injection of the plastic, or can be formed from conductive plastic. The present method reduces the cost and complexity of forming electrical components.

Abstract: A mold for assembling and forming a wire harness preferably includes wire supports extending into a continuous trough which forms a main trunk and a plurality of branches extending from the main trunk. A port introduces a generally liquid sheath material into the trough of the mold. Wires are routed on the wire supports along the main trunk and branches of the trough in the mold. The sheath material is then introduced into the mold and cures around and among the plurality of wires.

Abstract: A mold for forming a wire harness includes a trough having a concave surface. A plurality of wire supports extend into the trough for supporting a plurality of wires in the trough and spacing the wires away from the concave surface. A polymer sheath material is introduced into the trough, thereby encasing the wires.

Abstract: A mirror housing is formed of two colors in a two-stage molding process. An inlay of the first color is inserted into a mold, and plastic of a second color is molded to surround the inlay. In this way, a two-toned mirror housing is formed without the necessity of painting or masking.

Abstract: A wire harness for use on contoured, mounting surface includes individual wires bundled together. In an effort to protect these wires from mechanical wear, vibration, and water the wire harness is encased in foam. The foam is molded about the wire harness so that is surrounds the harness in the shape of the mounting surface. The foamed-in wire harness may have an elastic memory, so that it can be bent and resiliently recover to its molded shape.

Abstract: A component and wire harness combination includes a component comprising a panel having a channel with an opening. A plurality of wires are disposed in the channel. A sheath encases the plurality of wires in the channel, protecting the wires and retaining them within the channel.

Abstract: A wire harness includes a polymer sheath integrally formed splice locators and a molded slit for a repair wire formed integrally with the sheath. The wire harness includes a plurality of wires having a continuous sheath molded around the wires. The splice locator is generally axially aligned with the splice, thereby providing a visual indicator of the location of the splice. The splice locator is preferably molded in a visibly different cross section, diameter, and color from the sheath. The wire harness further includes a molded slit extending axially along the wire harness for receiving a repair wire.

Abstract: A wire harness includes a plurality of wires surrounded by a continuous molded sheath. The sheath includes a first section made of a first material and a second section integral with the first section and made of a second material different from the first material. The different materials provide different colors, such as for color-coding branches of the wire harness. The different materials also provide areas of increased abrasion resistance to mechanical wear, temperature resistance and chemical resistance.

Abstract: An improved vehicle headrest includes a bead between a plastic sleeve and a cloth facing. The cloth is bonded to the plastic sleeve such that an exposed face of the cloth is quickly and reliably connected to the plastic sleeve. The plastic sleeve is then filled with a foam and a positioning post. The inventive headrest is formed by initially placing the cloth material on positioning structure in an anvil. The plastic sleeve has been previously rotationally molded, and is slid onto the anvil and over the cloth material. A dielectric bar is then brought into contact with the plastic sleeve, and a bead is formed. As the bead is formed, a cutting blade cuts the plastic material inwardly of the bead. The cut portion of the sleeve is removed exposing the cloth material. A "RF" compatible barrier layer is formed on a rear face of the cloth material and prevents foam from reaching the exposed forward face.