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 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: 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: A load bearing floor mat for vehicle cargo compartments includes a pliable layer configured to overlie a defined area of a vehicle floor and also includes a rigid member that is associated with a portion of the pliable layer. The rigid member has a width that is sufficient to span a gap or opening in the vehicle floor, such as a spare tire well or other storage compartment. The rigid member renders the pliable layer substantially non-pliable above the opening such that the floor mat can support a load placed thereon.

Abstract: Apparatus for storing items within a vehicle compartment that can be operated single-handedly, are provided. A cover is pivotally attached to a vehicle compartment floor (or to a base secured to a vehicle compartment floor) and is movable between a closed position in overlying, face-to-face relation with the floor and an open position wherein the cover is disposed substantially transverse to the floor. A wall is pivotally attached to the cover front side and is movable between a stored position in face-to-face relation with the cover front side and an operative position disposed substantially transverse to the base and to the cover. A spring is configured to urge the wall to a predetermined position when the cover is moved from a closed position to an open position. An elastic strap is secured to the cover and is configured to secure articles placed between the elastic strap and the cover.

Abstract: Apparatus and methods are provided forming a sound attenuating laminate that has a decoupler fiber layer and a mass layer in opposing relationship with each other. The decoupler fiber layer and mass layer of the laminate are heated to the selected temperature in substantially the same amount of time via a hot air source and a heated platen, respectively. The heated laminate is conveyed to a mold and formed into a predetermined three-dimensional configuration via the mold.

Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.

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.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Air duct outlets for use on inclined surfaces within vehicles are provided. An air duct outlet includes a body having a fascia with an opening formed therein. A louver assembly is disposed within the fascia opening and is movable between a first position substantially flush with the fascia and a second position substantially nonflush with the fascia. The louver assembly includes a housing having an inlet and an outlet. A set of louvers are secured within the housing in spaced-apart adjacent relationship and are configured to adjust the direction of air flowing through the housing. An actuator extends from the fascia adjacent the opening and is operably connected with the louver assembly. Movement of the actuator within a first range causes pivotal movement of the louvers, and movement of the actuator within a second range causes pivotal movement of the louver assembly between the first and second positions.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Vehicle trim components are formed by applying a layer of material onto a mold surface and then selectively applying foam prior to molding operations. Selectively applying foam may include applying foam of different densities in multiple locations and/or applying foam of different thicknesses in multiple locations. The material and foam are subjected to conditions within the mold to produce a trim component having a desired shape. Once de-molded, barrier material may be added and various post-molding operations may be conducted.

Abstract: An apparatus for deploying an air bag through an automotive dash panel (12) includes an air bag door (16) integrally formed in the panel and defined by a door perimeter including a frangible edge (18) of reduced cross section. A dispenser (20) supports the air bag (24) behind the door. A metal reaction plate (28) is positioned between the air bag (24) and the door (16). When the air bag inflates, it forces the reaction plate (28) to bend around a horizontal hinge line (36). As the reaction, plate pivots it concentrates inflation force along a lower portion of the frangible door edge. This helps to predictably separate the door from the dash panel by tearing along the lower door edge and allowing the tear to propagate up two side edges. In one embodiment, the tear also propagates across an upper edge to completely separate the door from the panel. At least one, and preferably two or three tethers (50) limit how far the door can travel during air bag inflation.

Abstract: A molded floor covering for a vehicle floor includes a thermoplastic polymer layer with an integral, threaded drain tube extending therefrom. The drain tube is configured such that a distal end thereof can extend through a drain hole in a vehicle floor when the floor covering is installed within a vehicle. The drain tube includes a threaded bore that is configured to receive a correspondingly-threaded drain plug therein. A method of producing a molded floor covering having an integrally formed, threaded drain tube includes providing a mold having a contour of a vehicle floor with an outwardly projecting threaded member. A layer of thermoplastic polymer is vacuum formed over the mold and around the threaded member such that the layer follows the contours of the mold and threaded member to form an elongate tube extending therefrom.

Abstract: An air duct outlet that allows a user to redirect an air stream within a wide range of directions includes a housing having a planar first wall and a convexly-curved second wall in adjacent, spaced-apart relationship and that define an air passageway having an inlet and a flared outlet. A vane is pivotally attached within the air passageway and is movable within a range of positions that are increasingly transverse to the first wall. An air stream flowing through the air passageway is deflected by an amount that increases with each position of the vane in the range such that the air stream adheres to a portion of the second wall by an amount that increases with each position of the vane in the range and such that the air stream exits from the outlet in a direction that is increasingly transverse to a direction normal to the outlet.

Abstract: A driver-accessible storage drawer is slidably mounted to an instrument panel and is movable within a cavity of the instrument panel between closed and open positions. The storage drawer comprises a floor, a front wall, a rear wall opposite the front wall, and side walls that extend between the front and rear walls in spaced-apart relationship to define a storage compartment for receiving items therein. A tray having one or more receptacles therein is slidably secured to the storage drawer and is movable between a hidden position within the instrument panel cavity and an exposed position when the storage drawer is in an open position.

Abstract: Air duct outlets provide automatic oscillation of air flow and also allow users to manually redirect air streams. An air duct outlet includes a housing having an air passageway that terminates at an air outlet. A drive source is operably connected to a reciprocating member and transmits reciprocating motion to the reciprocating member. An air-directing vane is pivotally attached within the air passageway and is movable within a range of positions to direct an air stream flowing through the air passageway and exiting from the outlet. An actuator extends from the housing and is movable between first, second and third positions. A user can manually pivot the air-directing vane via movement of the actuator between the first and second positions. When the actuator is moved to a third position, the reciprocating member operably engages the drive arm and causes the air-directing vane to oscillate automatically.

Abstract: Air duct outlets having remotely located joystick controls are provided. A first set of generally parallel louvers are pivotally connected in spaced-apart adjacent relationship. A second set of generally parallel louvers are pivotally connected in spaced-apart adjacent relationship in an upstream location from the first set of louvers. A joystick is remotely positioned and does not interfere with air flowing through the outlet. The joystick is operably coupled with the first and second sets of louvers and is configured to pivot the first and second sets of louvers in response to user movement thereof.