Abstract: A guiding pillar trim (14) for a side-curtain airbag system (12) of a vehicle (10) is provided. The guiding pillar trim (14) includes a panel (44) for covering a vehicle body structure (10). This panel (44) has a guide member (54) coupled thereto that is movable between a trim configuration and a ramp configuration. In the ramp configuration, the guide member (54) directs the deployment of a side-curtain airbag (34) in a predetermined direction.

Abstract: A console for a vehicle includes a console housing defining a storage compartment. The console housing also defines an indented area in an outer surface thereof. A bin is sized to fit within the indented area such that an entire internal surface area of the bin is contiguous with the indented area when the bin is closed.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

Abstract: A connector assembly is provided comprising a device including a conductive device shroud forming a device plug receptacle. A cable element includes a first stripped cable end portion exposing an internal cable conductor and a third stripped cable portion exposing a cable ground shield. A terminal element is mounted to the first stripped cable end portion. A ground busbar includes a cable mount end mounted to the third stripped cable portion and a ground terminal end. A conductive overmolded connector body is molded covering at least a portion of said third stripped cable portion and comprising a connector plug portion configured to fit within the device plug receptacle.

Abstract: An active keyed locking system (10) for a vehicle (12) includes a keyed actuated device (58). A position sensor (56) is coupled to the keyed device (58) and generates a position signal indicative of position of the keyed device (58). A controller (64) is electrically coupled to the position sensor (56) and enables a vehicle component in response to the position signal.

Abstract: A glove box is provided comprising an instrument panel substrate and a door panel rotatably mounted thereto. A push button assembly includes a latch element movable between a door panel engagement position and a door panel release position. The assembly farther includes a push button element including a button activation surface having a button height and a button width. The push button is in communication with the latch element to move it into the door panel release position. A rigid button housing is included having a rigid perimeter surrounding the button activation surface. The button height is insufficient to allow knee intrusion activation.

Abstract: A tire pressure sensor assembly is provided for use with a wheel rim including a valve hole. The sensor assembly including a metal valve stem element having a stem base, a stem body, a stem cap end, and an inner stem chamber. A lower sensor housing is rigidly over-molded onto the stem base and forms a sensor storage chamber. A tire pressure sensor element is mounted therein. An outer rubber seal is over-molded onto the stem body and includes an inner retention portion, an outer retention portion, and a retention groove configured to allow the metal valve stem element to be press-fit and retained into the valve hole. A plurality of vent holes are formed spaced around an outer perimeter of the stem base to allow universal orientation within the valve hole.

Abstract: A method and system for forming an injection molded plastic part. After the injection of plastic material has started, a volume of gas from a fixed volume reservoir is introduced into the plastic material at a low pressure forming a hollow cavity. The gas is introduced into the mold by a gas pin having a temperature sensing device, such as a thermocouple, positioned on it. The introduction of this volume of gas is initiated when the temperature of the plastic material in the mold has reached a predetermined value. After the mold is filled and packed with plastic, pressurized gas is introduced into the hollow cavity forming the completed plastic part.

Abstract: A vision system (10) for a vehicle (14) includes a light source (46) that generates an illumination beam (20). A receiver (62) generates a first image signal and a second image signal. The first image signal is generated in response to a reflected portion of the illumination beam (20). A controller is coupled to the light source (46) and the receiver (62). The controller generates an image in response to the first image signal and the second image signal.

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 automotive keyless smart-start assembly 10 for use in an automobile 22 is provided including an automotive engine 18 having an operating condition and a stopped condition. An ignition controller 16, having a locked state and an unlocked state, is in communication with the automotive engine 18. A receptacle bin 20 is mounted to the automobile 22 and is in communication with the ignition controller 16. The receptacle bin 20 is movable between a closed position 34 and an open position 32. A portable electronic transmitter element 12, including a security code 14, communicates the security code 14 to the ignition controller 16 upon being positioned within the receptacle bin 20. The ignition controller 16 verifies the security code 14 and moves to the unlocked state upon verification. The receptacle bin 20 moves to the closed position 34 upon verification.

Abstract: An automotive center stack panel assembly is provided comprising an automotive instrument panel assembly having a recessed display chamber. A video display panel assembly is mounted within the recessed display chamber. A rear pivot link assembly is included having a rear first fixed pivot end rotatably mounted to the automotive instrument panel assembly and a rear second fixed pivot end. A forward pivot link assembly is included having a forward first fixed pivot end rotatably mounted to the automotive instrument panel assembly and a forward second pivot end. A control panel includes an upper control panel end and a lower control panel end and a control panel slot guide. The rear second fixed pivot end rotatably is mounted to the upper control panel end and the forward second pivot end slidably is mounted within said control panel slot guide.

Abstract: A switch actuator assembly is provided comprising a circuit board housing including an upper housing and a lower housing forming a board compartment. A circuit board assembly, mounted within the board compartment, includes a switch element. A button assembly, positioned remotely from the upper housing, includes a cantilever button element. A plunger array assembly is included comprising a plunger array frame and a plunger element. The plunger element comprises a main plunger piston having a first plunger end configured to engage the cantilever button element only in a radial direction and a second plunger end configured to transfer force to the switch element. A plunger cantilever arm has a first cantilever end affixed to the plunger array frame and a second cantilever end affixed to the main plunger piston and is mounted in a mount position configured to minimize horizontal displacement of said second plunger end.

Abstract: A method and system for controlling a fluid-assisted injection molding process for producing a molded plastic article. The fluid can be gas, water or another fluid. One or more pressure transducers are positioned in the mold cavity and generate signals to control the initiation of the pressurized fluid, the packing of the material in the mold and/or the switchover from the packing phase to the holding phase. The transducers can be positioned at or near the gate or pre-gate, at or near the fluid channel area, and/or at or near the end of the fill area.

Abstract: A method of manufacturing an automotive door armrest is provided and comprises molding an armrest support surface into a lower door panel. A frame assembly is formed to comprise at least one through socket having an open upper socket face and an open lower. The frame assembly is overmolded such that an overmold surface is formed over the open upper socket face. A foam bun is inserted into the lower socket face. The frame assembly is mounted onto the armrest support surface such that the foam bun becomes secured within the at least one through socket. The frame assembly is affixed to the lower door panel.

Abstract: A plastic product for particular use as grab handles, door closure handles, and other trim and component products. A foam core, either structural or non-structural, is over-molded with a hard or soft plastic shell or skin. Structural members for heat staking, mechanical fastenings, and the like, are integrally formed on the ends of the handles in order to affix the handles to a door pillar, door panel, or the like.

Abstract: A locking system (12) for a mold (14) includes a first mold half (20), a second mold half (22), and a lock assembly that is coupled to one of the mold halves (20, 22). The lock assembly includes a wear plate (80), that is disposed between the first mold half (20) and the second mold half (22), and an adjustment element (86), which is disposed between the wear plate (80) and one of the mold halves (20,22). The lock assembly also includes a wear plate locking fastener (84), that locks the position of the wear plate (80), and an adjustment fastener (88), which is separate therefrom and adjusts the position of the wear plate (80).

Abstract: An automotive slouch rear seat with improved adjustability is provided including an upper seat back and a lower seat bottom. The upper seat back includes a fixed rear seat back, a pivotal seat back, and a sliding seat back. The pivotal seat back has an upper end and a lower end for connecting to the lower seat bottom. The sliding seat back is slidably engaged to the fixed rear seat back. The sliding seat back is rotatably engaged to the upper end of the pivotal seat back. The lower seat bottom includes a fixed rear seat bottom, and a sliding seat lower. The sliding seat lower is slidably engaged to the fixed rear seat bottom. The sliding seat lower is rotatably engaged to the lower end of the pivotal seat back. Also, an automotive slouch rear seat assembly and a method of assembling a pre-installation automotive slouch rear seat assembly are provided.

Abstract: An automotive seat assembly 10 is provided, including a primary seat structure 12 having a seatbase portion 14 and a seatback portion 16. The present invention further includes a headrest support assembly 26 including an upper headrest support section 28 and a lower headrest support section 30 rotatable about a headrest pivot point 34 positioned between the upper headrest support section 28 and the lower headrest support section 30. An energy absorbing deformable plate 40 is mounted to the lower headrest support section 30 at an upper plate end 42 and is mounted to the primary seat structure 12 at a lower plate end 44. The energy absorbing deformable plate 40 is deformable rearwards 43 during a rear-end collision. As the energy absorbing deformable plate 40 deforms rearward, the upper plate end 42 moves the lower headrest support section 30 rearward and the upper headrest support section 28 is thereby rotated forward.

Abstract: An automotive center stack panel assembly is providing comprising an automotive instrument panel assembly having a recessed display chamber formed therein. A video display panel assembly is mounted within the recessed display chamber. A pivot link assembly has a first fixed pivot end rotatably mounted to the automotive instrument panel assembly and a second fixed pivot end. A control panel has an upper control panel end and a lower control panel end. The second fixed pivot end is rotatably mounted to the upper control panel end such that the control panel is pivotable between a display hidden position and a display exposed position. The control panel covers the recessed display chamber when in the display hidden position.