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: An improvement in the fit and finish of a center stack or console area of a vehicle is provided by integrating individual electronic module faceplate and trim bezels into a single faceplate which may be positioned independent of the individual modules. A jumper or flat wire connector provides communication between the controls on the faceplate and the module. A molded alignment guide is provided to direct pass-through media through a slot in the faceplate and into the module.

Abstract: The present invention is directed at an improved method for forming two-tone trim panels for automobiles and the like, wherein the color demarcation line between color regions of the panel skin may be hidden in a narrow groove or joint. The groove in the formed skin may be formed by the expansion pressure of foam conforming the skin to a narrow projection in a foam mold. Alternatively, a narrow groove may be formed by skiving or embossing along the color demarcation line.

Abstract: An apparatus for use in a motor vehicle having a roof system, the motor vehicle further having a body with a passenger compartment and a trunk space, the apparatus comprising a roof system comprising any one of a rigid panel hardtop, a retractable hardtop moveable from an extended position disposed above the passenger compartment to a retracted position, or a soft convertible top movable from an extended position disposed above the passenger compartment to a retracted position, wherein any one of the rigid panel hardtop, retractable hardtop or convertible soft top includes an attachment bracket. A transverse support beam having a first end and a second end is included, the support beam carrying any one of the rigid panel top, the retractable hardtop or the soft convertible top, wherein the first end and said second end include universal adapter brackets. The universal adapter brackets are connected to the attachment brackets and to the vehicle body.

Abstract: A portable storage device and filing system is provided for use in a transportation vehicle. The system comprises a case which may be engaged with an interior trim component, such as an interior sidewall, and the device may appear to be part of the interior vehicle trim. The device may be accessed by articulating the sides of the case away from one another to expose the interior of the case. The interior of the case may include an expandable compartment having dividers or folders for storage and organizing of loose pieces of paper. The case may be trimmed to coordinate with the interior theme of the vehicle when stored in the vehicle.

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: The present invention relates to a slidable armrest that may be used in combination with a console within a transportation vehicle. The armrest may be slidably mounted to a mounting bracket and overlie a console lid/compartment and be moveable forward to provide arm support for vehicle occupants or rearward to allow access to an underlying storage compartment. Two exemplary embodiments of actuating mechanisms for controlling fore/aft positioning of the armrest are 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 method of manufacturing decorative plastic composites having a decorative layer, a backing layer and a clear outer layer which provides exceptional “depth of image” is disclosed. Decorative or protective appliqués' having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a clear outer layer on the top surface of a thin foil, film, fabric or veneer. A method is also disclosed for coating the exposed surface of the decorative layer between injection of the backing and outer layers to impart a desired visual effect or repair the surface.

Abstract: An expandable/collapsible apparatus is provided for storing items within vehicle compartments that may be manipulated into an operative position or into a closed position. The apparatus may include a plurality of panels that are pivotally attached to one another so that the apparatus is movable between a closed position beneath, e.g., an upper panel or roof portion of a vehicle and an open position expanded for receiving items for storage. A spring loaded latch may be provided for securing the apparatus in either a collapsed or expanded (drop-down) position. Access to the apparatus may be through the trunk or rear cargo area of a vehicle or through a door formed in the package shelf of a vehicle.

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: A water management system for convertible tops for motor vehicles is provided. The system attaches to a rear edge of the folding top, generally below the rear window and collects water which runs or sheets rearwardly off the surface of the top to direct the water to drainage tubes and expel the water from the vehicle.

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: 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: 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 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: 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.