Abstract: An energy management system includes a bolster panel configured to attach to vehicle structure and a plurality of ribs connected to the bolster panel. Each rib is deflectable during a vehicle impact. The bolster panel and the plurality of ribs are unitary and formed as one piece. The plurality of ribs are arranged in a manner forming an energy absorption pattern that is progressive. A second energy management system includes a bolster panel configured to attach to vehicle structure, a plurality of ribs connected to the bolster panel, and a steering column support structure connected to the bolster panel. The bolster panel, ribs, and steering column support structure are unitary and formed as one piece. A method for creating the energy management system is also disclosed.

Abstract: A vehicle interior trim panel comprising a mounting opening with opposing walls for slidably engaging a component into fixed relationship with the mounting opening wherein molded features in the walls of the mounting opening engage the component to align and fixedly retain the component in the mounting opening. In addition, a locking system for preventing theft is disclosed.

Abstract: An umbrella holder for a vehicle is provided, comprising a tube for receiving a collapsed umbrella, wherein the tube may be integrated into an end portion of an instrument panel. The tube may be angled downward and vented for drainage to the outside at a lower end. The upper end of the tube may cooperate with a depression in the adjacent door panel to allow the handle of the umbrella to protrude from the end of the instrument panel for relatively easy access when the vehicle door is opened.

Abstract: An air duct outlet housing has spaced-apart top and bottom walls, and spaced-apart first and second side walls that define an air passageway with an inlet and outlet. First and second air deflection members include elongated first and second panels with respective proximal and distal end portions. A flange extends from each distal end portion of the respective first and second panels. The first and second panel proximal ends are pivotally secured to the housing and are movable between first and second positions. The first and second panels are in face-to-face relationship with the respective first and second side walls when in respective first positions. The first and second panels extend in respective directions that are transverse to the respective first and second side walls when in respective second positions.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: A lighting device especially suitable for automotive center-high-mounted-stop-light (CHMSL) and brake light applications is provided. The lighting device comprises a display panel having at least two interfaces therein, with at least one interface configured as a light reflective interface and at least one interface configured as a light emitting interface. At least a portion of light from a light source propagates through the display panel into contact with the light reflective interface and is reflected by the light reflective interface towards the light emitting interface using total internal reflection.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs. A tether is included that engages with the molded features in the reaction plate whereupon airbag deployment the tether is not retained by the first molded feature but is retained by the second molded feature.

Abstract: The present invention relates to an apparatus and method of perforating the cover layer or soft skin of an automotive trim panel such as an instrument panel with a laser to allow light to bleed through the perforations. The light source would preferably be a low heat generating or “cool” type source such as an LED. The light source would be attached to a suitable substrate or incorporated in to a flexible printed circuit and coupled to the vehicle electrical system. This method would enable fill switch integration to a trim panel and provide a seamless styling opportunity regarding the electrical controls. This method would help reduce cost and weight, improve quality, and promote new seamless styling theme.

Abstract: An air duct outlet includes a housing having spaced-apart top and bottom walls, and spaced-apart first and second side walls extending between the top and bottom walls to define an air passageway having an inlet and outlet. A first air return passageway is located adjacent to the first side wall, and diverts a portion of an air stream flowing through the air passageway as the air stream adheres to the first side wall. A second air return passageway is located adjacent to the second side wall, and diverts a portion of an air stream flowing through the air passageway as the air stream adheres to the second side wall. The continuous diversion of portions of an air stream flowing through the air passageway by the first and second air return passageways causes an oscillating, sweeping motion of the air stream as it exits from the air passageway outlet.

Abstract: Sound absorbing/sound blocking products, including trim products formed from a porous fibrous layer backed by a sound absorbing layer and a sound blocking layer for use within vehicles, and methods of making same, are provided. A porous fibrous layer structure including a fibrous layer backing is heated to achieve a fluid or semi-fluid state and then subjected to vacuum to draw air through the fibrous layer backing to create a porous structure. A layer of sound absorbing and a layer of sound blocking material may be applied to the porous fibrous layer backing to provide improved acoustic properties. An underlayment may further be included to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: An air bag door construction for air bag deployment comprises a trim panel and air bag door of unitary construction, at least a portion of the door defined by an area of reduced cross-section outlining at least a portion of the periphery thereof. One or more tethers are formed in the panel, outlined by an area of reduced cross-section, preferably in a dovetail shape which does not direct the propagation of tearing into the tether. A tear stop may be formed at the ends of the tether. The improvement comprises a stiffening frame that is attached to the backside and/or the topside of the panel just outboard of the air bag door periphery but not located across the tethers to improve deployment performance.

Abstract: A method for annealing a structure formed by electrodeposition is provided, the method comprising providing the electrodeposition structure, the electrodeposition structure comprising an electroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: The present invention relates to the formation of a double angle V-groove in the backside of plastic shells to provide a preweakened section for a vehicle application. The double angle V-groove may be located at the airbag deployment opening of a vehicle.

Abstract: A structure for supporting an instrument panel by a defroster nozzle so that sufficient rigidity can be imparted to the top of the instrument panel. A supporting member is attached to an upper wall of the defroster nozzle arranged inside the instrument panel and is disposed in contact with the instrument panel to support same.

Abstract: An airbag door construction for airbag deployment comprising an instrument panel having an area outlining at least a portion of an airbag door. A reaction plate is attached to the underside of the panel at the airbag door location. The reaction plate contains first and second molded features, each such feature having a flexural strength (Fs), wherein the first molded feature's Fs is lower than the second molded feature's Fs.

Abstract: A trim panel for a vehicle containing a vehicular antenna system comprising a substrate, an outer skin and a foam disposed between the substrate and the outer skin. An antenna/circuitry system (2) is located on the upper surface of the substrate (1) and is in contact with the urethane foam (7), the antenna/circuitry system (2) comprising an insulating base layer (12) including upper and lower surfaces and an electro-conductive antenna layer on the upper surface of the base layer (12) and an electro-conductive circuit layer on the lower surface of the base layer (12).

Abstract: An apparatus and method for molding plastic materials is provided comprising a mold having a first mold section (12) and a second mold section (14) with a mold cavity (16) disposed in between. A first gate design is provided by at least one first gate design mold member (40), and a second gate design is provided by at least one second gate design mold member. The first and second gate design mold members are removably attachable to, and interchangeable on, at least one of the first or the second mold sections (12, 14) to change from the first gate design to the second gate design.

Abstract: Sound absorbing/sound blocking products, including trim products formed from a porous fibrous layer backed by a sound absorbing layer and a sound blocking layer for use within vehicles, and methods of making same, are provided. A porous fibrous layer structure including a fibrous layer backing is heated to achieve a fluid or semi-fluid state and then subjected to vacuum to draw air through the fibrous layer backing to create a porous structure. A layer of sound absorbing and a layer of sound blocking material may be applied to the porous fibrous layer backing to provide improved acoustic properties. An underlayment may further be included to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: A variety of embodiments are disclosed, in both apparatus and method form, that relate to the use of fabric material in the manufacture of an air bag deployment system. In addition, fabric weakening is disclosed according to a technique that does not result in physical alteration of the fabric. This invention therefore includes an air bag cover for an air bag safety system for a vehicle comprising a fabric outer layer having a frontside and a backside and a substrate containing an opening wherein the opening has a periphery. The substrate is preferably formed by low pressure molding, wherein the fabric outer layer overlies the opening in the substrate, and wherein the fabric outer layer is weakened at a location that is adjacent or overlies the substrate opening periphery.

Abstract: Light weight acoustic carpet including porous carpeting backed by a primary sound reducing layer and localized secondary insulators for use within vehicles, and methods of making same, are provided. A porous carpet structure including a carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of sound absorbing or insulating material may be applied to the porous carpet structure to provide improved acoustic properties. Secondary sound reducing absorbers/insulators may further be included as part of the molding process to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: An apparatus and method are disclosed for holding a generally cylindrical workpiece for honing or otherwise machining an internal bore. The workpiece is held by a gripping surface over most of the innermost turn of a spirally wound spring and coil. The workpiece is grasped circumferentially over its outer surface without excess contact pressure at any particular point. A tendency of the machining operation to rotate the workpiece serves to secure the workpiece more tightly in position by tightening the outer turns of the spring band coil. A rotatable tensioning member acts under the influence of a biasing spring to decrease the diameter of the innermost turn of the spring band coil to bring the gripping surface into contact with the workpiece. A method for adapting the work-holding apparatus to smaller or irregularly shaped workpieces consists of molding an annular piece around the workpiece.