Abstract: A vehicle seat assembly for detecting a condition of the seat assembly. The vehicle seat assembly includes a seat cushion. The vehicle seat assembly also includes a vehicle occupant sensing system having a plurality of sensor assemblies. Each sensor assembly includes a base and an upper slide member. The upper slide member is supported for movement toward and away from the base in response to a condition of the seat cushion. Additionally, the vehicle seat assembly includes at least one seat cushion insert having a topside and an underside. The seat cushion insert is disposed between the seat cushion and the sensor assemblies, and the topside has at least one planar section.

Abstract: A barrier panel adapted for operative attachment to a vehicle door panel. The barrier panel includes a main body portion and at least one tab adapted for operative attachment to the vehicle door panel. The tab extends from the main body portion and is removable from the main body portion. Furthermore, the barrier panel may be employed in a vehicle door assembly for facilitating reassembly of the same. A method of manufacturing the vehicle door assembly is also disclosed.

Abstract: The present invention provides a method of testing a sensor array that is incorporated into a vehicle seat. The method includes the steps of placing a seat pan and cushion assembly having a seat trim cover and a sensor array into a seat build fixture and electrically connecting the sensor array to an electrical testing device capable of determining the actuation of the sensors in the sensor array. The method further includes the steps of determining if the sensors are at a predetermined unloaded output value, activating the seat build fixture to apply compression force to the seat pan and cushion assembly, and determining if the sensors have changed output values where the change corresponds to a predetermined amount. The method also includes the steps of mounting the seat trim cover to the bottom of the seat pan in a predetermined manner to form a completed lower seat assembly and de-activating the seat build fixture to release compression force from the completed lower seat assembly.

Abstract: A method of determining an equivalent output value for a failed sensor in a vehicle seat having an occupancy sensing system. The method includes the steps of sensing the output of each sensor in an array of sensors that detect a physical presence in the seat. If the output of the sensor falls below a predetermined value, exceeds a predetermined value, or remains fixed the sensor is classified as inoperative. The method then calculates an equivalent sensor output value for any sensor classified as inoperative and applies the sensor array output values for each operable sensor in the array and the calculated equivalent output value for any inoperative sensor to a neural net. Then, the applied sensor output values are recognizing as falling within one of a group of predetermined classification patterns that represent a physical presence in the seat defined by size, weight, and physical orientation.

Abstract: A vehicle occupant sensing system including a circuit carrier, an electric circuit with leads, and a sensor with a body and a plurality of formed terminals. Each of the terminals has a lower portion spaced a predetermined distance away from a plane defined by the bottom surface of the body. Moreover, the system has a plurality of conductive connectors each including a blade extending into the circuit carrier and into electrical communication with a lead of the electric circuit. The body is supported on the circuit carrier, and the terminals are supported by the top end of the connector. Also included is a method of manufacturing the same. The formed terminals allow the sensor to be more easily positioned relative to the connector, thereby facilitating assembly. Also, the connectors support the terminals when the connector attaches to the terminal, thereby inhibiting damage to the terminals that could otherwise occur.

Abstract: The present invention provides a vehicle information display and communication system having a plurality of operative modules, the system includes a control processing unit adapted to provide an interface among the plurality of operative modules. The operative modules include a display module adapted to provide visual information to the occupants of the vehicle, a navigation module adapted for global positioning satellite reception to provide vehicle position information to the control processing unit, and a telecommunications module adapted for wireless communication to provide communication between the control processing unit and a wireless telecommunications network and between the control processing unit and any one of a plurality of local wireless devices.

Abstract: This invention relates to a center stack face plate that has an integrated HVAC duct assembly. This invention removes many parts and assemblies from typical HVAC duct assemblies and provides complete integration of HVAC duct assembly within the center stack face plate. The connector duct and air conditioner housing along with the barrel assembly make a direct point of connection with the center stack face plate allowing for typical usage of an HVAC system in a more streamlined fashion.

Abstract: This wrapped bolster seal comprises at least two door panels, where one is a wet side door panel and another is a dry side door panel disposed opposite the wet side door panel; at least one rib extending from the side of the wet side door panel disposed proximate the dry side door panel; and at least one edge layer wrapped about a top edge of the wet side door panel and extending at least partially along the side of the wet side door panel disposed proximate the dry side door panel. When the wet side door panel and dry side door panel are joined, the rib creates a seal disposed between the wet side door panel and the dry side door panel adapted to reduce moisture from contacting the edge wrapped layer.

Abstract: A vehicle seat assembly that includes a seatback frame and an upper armature moveably supported by the seatback frame. The upper armature includes a head restraint and a first impact body, and the upper armature is operable to move in response to a predetermined force applied to the first impact body to thereby move the head restraint toward the occupant. The vehicle seat assembly also includes a lower armature that is operatively connected to the upper armature and is operable to move toward the upper armature in response to a predetermined force applied to the lower armature and act on the upper armature to move the head restraint toward the occupant.

Abstract: A vehicle occupant sensing system for detecting a condition of a vehicle seat. The system includes a circuit carrier, an electric circuit with a plurality of leads, and at least one sensor that has a plurality of terminals. Also, the system includes a plurality of conductive connectors associated with the corresponding terminals and leads. The connectors each include a body disposed for electrical communication with the associated terminal and include at least one deformable blade. The blade extends into the circuit carrier and into electrical communication with the associated lead of the circuit, thereby mechanically attaching the conductive connector to the carrier while providing electrical communication between the sensor and the circuit. Also included is a method of manufacturing the same. By piercing the carrier and the circuit, the blade establishes a more robust mechanical and electrical connection for the sensor, thereby increasing the operating life of the system.

Abstract: A method of recognizing and classifying the occupancy in a vehicle seat having an occupancy sensing system, including the steps of sensing the output of an array of sensors that detect a physical presence in a seat and applying the sensor array output as a vector representation to a neural net that was trained using a learning vector quantization algorithm. The method also includes the step of recognizing the sensor array output as falling within one of a group of predetermined classification patterns that represent a physical presence in the seat defined by size, weight, and physical orientation.

Abstract: An injection molding system for forming a molded plastic part including a die having a pair of die halves which mate along their joining surfaces to form a parting line and define a mold cavity, a plurality of ejection pins within at least one of the die halves and operable to move the finished molded part in a direction away from at least one of the die halves, a gate removably mounted to one of the die halves, and a runner. The gate includes an inlet and an outlet having an edge surface extending in a direction generally opposite to the movement of the molded part upon ejection from the mold cavity. Upon separation of the two die halves, the ejection pins are then further operable to remove excess cooled plastic material from the gate and the runner.

Abstract: A vehicle seat assembly of the present invention includes a seat backrest, a seat bottom, and a backrest reclining assembly. The backrest reclining assembly has an axis of rotation and includes a base, a rotating latching mechanism, and a reclining arm. The reclining arm is mounted to the seat backrest, the rotating latching mechanism is mounted between the reclining arm and the base such that the reclining arm and the seat backrest may be selectively rotated relative to the base about the axis of rotation. A pivot arm is mounted to the base and has a pivot axis point disposed at a predetermined distance from the axis of rotation of the reclining assembly. A locking arm is rotatively mounted to the pivot arm about the axis of rotation of the reclining assembly. A support arm is mounted to the seat bottom and rotatively mounted to the pivot arm at the pivot axis point, such that the pivot arm and the seat backrest may be rotated about the pivot axis point between an upright position and a folded position.

Abstract: The present invention relates to a method of manufacturing an interior trim panel assembly having an integrated soft-touch area for improved aesthetic trim component quality. The method of manufacturing a trim panel assembly for the interior of a vehicle having an integrated soft-touch area of the present invention includes placing a molded trim panel including a coverstock having an exposed outer surface and a foam backing disposed opposite the outer surface and a rigid substrate having at least one aperture bonded to the coverstock into a mold cavity. The method of manufacture further includes separating the bonded coverstock and rigid polymer substrate in a localized area to define an internal chamber accessible by the aperture. The method of manufacture also includes injecting soft foam into the internal chamber through the aperture so as to be juxtaposed between the coverstock and the rigid polymer substrate in at least one predetermined location to define an integrated soft-touch area.

Abstract: The present invention relates to a modular door trim panel assembly having an integrated seal for use in an automotive interior including a molded substrate having a first side defining an A-side surface visible from the interior of vehicle and a second side opposite the first side defining a B-side surface. The substrate includes a pair of side terminal edges and a lower terminal edge extending therebetween. The modular door trim panel assembly further includes at least one seal co-molded while the substrate is formed and bonded to the B-side of the substrate. The seal extends substantially parallel to the pair of side terminal edges and the lower terminal edge of the substrate and prevents the entry of moisture between the B-side of the substrate and the vehicle door. The present invention also relates to a method of molding the modular door trim panel assembly having an integrated seal.

Abstract: A vehicle seat assembly including a seatback frame and a lumbar support system operatively mounted to the seatback frame. The lumbar support system includes a lower suspension mechanism that is generally aligned with the pelvic and lumbar regions of the occupant of the seat assembly. The lower suspension mechanism includes a band of flexible material that is stretched about a pair of upstanding support members so as to have a predetermined tension for providing support for the occupant of the seat assembly at the pelvic and lumbar regions.

Abstract: A trunk space storage system for motor vehicles comprising a movable wall. This movable wall is located on the floor of the trunk space and acts as a new back wall of the trunk space. This movable wall slides along tracks on the floor of the trunk space to a position the user desires. The movable wall further comprises a wall extension to increase the wall height. This invention allows users to utilize as much of the trunk space as necessary without having the problem of having objects roll into the deep trunk space which can be difficult for many people to access.

Abstract: A torqued, error proofed for installation, chuck free helical head restraint guide that includes a head restraint guide assembly with at least two stems, a button sub assembly, and a bezel. The stems include a helix at one end of each stem and a multi-point socket head, an open wrench flat, and/or an internal torx head and crush ribs at the other end. The head restraint guide also includes a motor vehicle passenger seat that includes an upper cross member of a back frame with upper and lower openings. The head restraint guide further includes a head restraint assembly with head restraint posts and a head restraint pad.

Abstract: An overhead console bin for motor vehicles that allows the interior of the storage bin to be illuminated without illuminating the entire interior of the motor vehicle. This console bin comprises a storage bin, a plunger switch, and at least one lighting source. When the storage bin is opened the plunger switch turns on the at least one lighting source highlighting the interior contents of the storage bin. When the storage bin is in its stowed position, the at least one lighting source is turned off.

Abstract: A cargo management system for a motor vehicle with at least one seat well comprising a pouch of being deployed in said seat well. This pouch provides a lightweight, easy to use, unique storage management system for seat wells, a part of the vehicle which normally would not be an ideal storage area.