Abstract: An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.

Abstract: An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.

Abstract: A method of manufacturing an airbag assembly and a trim component for vehicle including the step of providing a first mold structure having a first surface formed therein, a second mold structure having a second surface formed therein and a third mold structure having a third surface formed therein. The first mold structure and the second mold structure are positioned to define a first cavity. A first material is introduced into the first cavity to form a substrate. The substrate and the third mold structure are positioned to define a second cavity. A second material is introduced into the second cavity to form at least one of a portion of an airbag assembly and an outer layer overmolded onto the substrate. Additionally, a scrim material may be disposed within the second cavity to produce a hinge having an embedded layer of scrim material.

Abstract: A method and apparatus for forming an interior component part having a relatively rigid substrate portion and a padded portion. The molding tool used to form the substrate portion includes a first mold part and a second mold part that form a substrate molding cavity into which a thermoplastic olefin is injected. The padded portion is formed by the first mold part and a third mold part that define a pad forming cavity. A mixture of a thermoplastic elastomer and a blowing agent is injected into the pad forming cavity. The expanded blown elastomer is enveloped within a skin formed when the blown elastomer contacts a cooled mold surface.

Abstract: An injection molding system (10) includes a first mold half (20) and a second mold half (22), which forms a cavity (23) with the first mold half (20). A cavity intrusion element (34) is displaceable to extend within the cavity (23). A displacement mechanism (36) is coupled to the cavity intrusion element (34). A controller (38) is coupled to the displacement mechanism (36) and controls the intrusion depth (D) of the cavity intrusion element (34) during an injection molding process. A method of forming an article includes the pressurizing of the cavity (23) within a mold (14) via a gas. A material having a blowing agent is injected into the cavity (23). The gas pressure within the cavity (23) is released. The cavity intrusion element (34) is backed out from within the cavity (23). The material is cured.

Abstract: An energy absorption device for use in a vehicle interior includes a first body having a protrusion defining an axially extending outer serrated surface, and a second body having a cavity defining an axially extending inner serrated surface. The protrusion is at least partially inserted into the cavity to at least partially support the first body relative to the second body. Upon an impact at least partially in the axial direction, one of the protrusion and the cavity is moved relative to the other to absorb at least some of the impact energy. An energy absorption vehicle interior assembly includes an energy absorption device connected between an interior vehicle trim member and a vehicle trim mounting member.

Abstract: A method of making a part includes introducing expandable material into a cavity of a mold containing a substrate, the mold including at least one projection extending into the cavity. The method further includes retracting the at least one projection to allow the expandable material to expand in the cavity, such that the expandable material forms an expanded material layer on the substrate.

Abstract: An interior vehicle trim panel includes a substrate having a front face and an under face. The under face has a tear seam to allow an airbag to exit the substrate when the airbag is deployed. The tear seam defines an airbag door. The outer layer is bonded to the front face of the substrate. A portion of the outer layer defines a hinge member for the airbag door. The outer layer is preferably mechanically bonded to the substrate in a mold, thereby forming an overmolded interior vehicle trim panel. Preferably, the hinge member of the outer layer is thicker relative to a region of the outer layer adjacent the airbag door.

Abstract: The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

Abstract: In at least certain embodiments, the present invention relates to automobile interior trim panel having an insert molded trim cover sheet. In at least one embodiment, the automobile interior trim panel is made by providing a trim cover sheet within a first mold cavity and introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the trim cover sheet. In this embodiment, the door panel portion has a first upper door panel portion having a portion circumscribing the trim cover sheet and a lower door panel portion below the first upper door panel portion. The method further comprises providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to at least a portion of the first upper door panel portion.

Abstract: In at least certain embodiments, the present invention relates to a trim panel made by providing a molding tool system comprising a first mold half, a second mold half, and a third mold half and positioning the first mold half and the second mold half proximate each other to form a first mold cavity. In certain embodiments, the method further comprises introducing a first resin into the first mold cavity to form a trim panel skin and positioning the first mold cavity with the trim panel skin and the third mold half with a trim panel substrate spaced from the trim panel skin to form a second mold cavity. In this embodiment, the method further comprises introducing a second resin into the second mold cavity to form a resilient layer extending between and connecting the trim panel skin and the trim panel substrate.

Abstract: A modular floor storage system that may be easily and quickly mounted, dismounted, and locked into position without the need for elaborate mounting track systems. Further the modular floor storage system may be configured in many ways by the user and located in several locations within the vehicle. Electrical connection may also be provided allowing power to be supplied for purposes such as battery-charging, lighting and the incorporation of cooling or heating capacity to the storage system.

Abstract: In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

Abstract: A method of making automobile interior panels includes a step in which a first insert is positioned in the cavity formed by a first and second mold section. The first insert is trimmed by a first lifter to form a trimmed first insert. A first resin is subsequently introduced into a second mold cavity such that this first resin bonds to the trimmed first insert. Complex interior panels are formed by utilizing additional lifters and/or mold sections to define mold cavities and paths for introducing additional resins.

Abstract: In at least certain embodiments, the present invention relates to an automobile trim panel with an insert molded decorative component. In at least one embodiment, the automobile interior panel is made by a) providing a molding tool comprising a first mold half and a second mold half that cooperate to form a first mold cavity, b) providing an insert component within the first mold cavity having a substrate made of a first material, and a decorative portion made of a second material less rigid that the first material, with the first mold half, the second mold half, and the insert component forming a second mold cavity, and c) introducing a resin into the second mold cavity to form a panel secured to the insert component.

Abstract: A cross beam assembly extends between side frame members of a vehicle and includes a beam having a hollow interior. The beam defines an opening formed therein. The assembly further includes an air bag inflator assembly having a source of pressurized gas for expelling gas to inflate an air bag. The inflator assembly is disposed within the hollow interior of the beam such that activation of the inflator assembly expels gas through said opening.

Abstract: The present invention provides for an improved bolster with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, the bolster includes a substrate formed by co-injecting a first and second material into a first shot mold cavity in a first shot of a molding operation. In a second shot mold cavity, a cover is formed on at least a portion of the substrate by co-injecting into a mold chamber a third and fourth material in a second shot of the molding operation. The fourth material defines an outer skin surrounding the third material which may include a foamed material to provide a soft, light cellular inner core such that when a force is applied to the cover, the outer skin will deform and compress the inner core, providing a soft feel to the bolster.

Abstract: An interior vehicle trim panel includes a panel body having a front face and an under face. The under face has a tear seam to allow an airbag to exit the panel body when the airbag is deployed. The tear seam defines an airbag door. A sheet of hinge material attached to the under face of the airbag door of the panel body. An airbag collar is attached to the under face of the panel body about the airbag door. An airbag housing is attached to the airbag collar, such that a portion of the sheet of hinge material is secured between the airbag collar and the airbag housing, thereby forming an interior vehicle trim panel.

Abstract: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

Abstract: Interior trim assemblies for automobiles that eliminate gaps between the trim assemblies and adjacent components in the interior of the automobile. The trim assemblies comprise rigid substrate members with pliable cover layers disposed on the rigid substrate members. In one embodiment, the substrates include central and lateral sections connected by the pliable cover layers. The lateral substrate sections may be deformed toward the central substrate section to accommodate variations in spacing between components, and to eliminate gaps therebetween. In another embodiment, the cover layers include resilient, non-corrugate free ends that extend outwardly from edge portions of the rigid substrates to define flexible flanges that contact adjacent automotive components to eliminate gaps between the trim assemblies and the adjacent components.