Abstract: An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.

Abstract: A method is provided for forming a welt in a single sheet of coverstock by folding and sewing. A second method is provided for forming a welt adjacent a seam formed by sewing two sheets of coverstock together, the method requiring less selvage from one of the sheets.

Abstract: An energy absorber for an overhead system in a vehicle includes a molded member having one or more corrugated sections, the corrugated sections including a plurality of channels wherein the channels include a top wall and a pair of spaced apart horizontally extending side walls and a base portion extending between channels. The energy absorber may be tuned for a desired impact and be located between a vehicle roof and a headliner to provide occupant impact protection.

Abstract: An air outlet for directing and regulating air flow within the interior of vehicles is provided, the outlet preferably having 360° adjustability and a relatively uniform rotational effort. The outlet may comprise a plurality of louvers, a linkage, a louver ring and a bezel which mechanically fit together and further includes a spring which is inserted between the louver ring and the bezel which may compensate for tolerance build variations amongst the various components and provide the desired level and range of rotational resistance.

Abstract: An energy absorber for an overhead system in a vehicle includes a molded member having one or more corrugated sections, the corrugated sections including a plurality of channels wherein the channels include a top wall and a pair of spaced apart horizontally extending side walls and a base portion extending between channels. The energy absorber may be tuned for a desired impact and be located between a vehicle roof and a headliner to provide occupant impact protection.

Abstract: An energy absorber for a vehicle includes an elongate member having one or more corrugated sections, the corrugated sections including a plurality of channels wherein the channels include a generally planar front wall and a pair of spaced apart vertically extending side walls, and one or two at least partial end walls. The elongate member further includes a base section extending between channels and one or more flanges that may extend from the base. The energy absorber may be tuned for a desired impact and be located between a bumper beam and a fascia at the front or rear end of a vehicle to provide low speed impact protection.

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 relatively thin foil, film, fabric, veneer or sheet of paper.

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 decorative layer, the decorative layer comprising a relatively thin metal foil, film, fabric, veneer or sheet of paper having a digital image from an inkjet printer deposited on a front surface thereof. In one exemplary embodiment, the appearance of a wood veneer may be modified by digitally printing a burl pattern over the wood grain surface of the veneer prior to injection molding.

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.

Abstract: A gap hider is provided for closing an opening between the ends of an assist grip and a trim panel, the gap hider fitting into a recess in the ends of the assist grip such that no adhesive or fasteners are needed. The gap hider provides that the trim panel can be deployed from beneath a portion of the assist grip without effecting the side air bag deployment.

Abstract: An armrest is provided including a flexible skin overlying at least a portion of a substrate member, the skin coupled to substrate member, the flexible skin and the substrate member defining a cavity there between and an opening along one edge, and a foam bun insertable in the cavity to form the armrest, wherein the foam bun comprises a first foam portion which the flexible skin overlies and a second foam carrier portion which closes off the opening. The first foam portion has a hardness that is less than the hardness of said second foam carrier portion, the foam bun further including an integrally formed locking flange to engage with an edge of the substrate and an integrally formed skin lock to engage with an edge of the skin.

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. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

Abstract: An adjustable air vent assembly has a frame and a plurality of louvers pivotally mounted to the frame. The plurality of louvers is movable between a closed position and a diffuse position. In the closed position, each louver has an edge contacting an edge of at least one other louver to substantially prevent air from flowing through the plurality of louvers in the closed position. In the diffuse position a first louver is oriented along a non-parallel plane with respect to a second louver. A single actuator is provided for moving the plurality of louvers between the closed and diffuse positions.

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. Use of multiple layers of decorative film, clear plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects.

Abstract: An automobile door bracket includes an attachment section and a corrugated section. The door bracket is placed within an automobile door assembly to function as a side impact countermeasure.

Abstract: An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.

Abstract: A console assembly for a vehicle includes a console body defining an opening communicating with a storage bin. The storage bin has opposing side walls each having a groove formed therein. A sliding member is slidably mounted within the grooves of each of the side walls within the storage bin. A console cover is pivotally mounted to the sliding member and defines a cover assembly. The cover assembly is slidably movable between a closed position wherein the console cover covers the opening of the console body and a partially open position wherein a portion of the opening of the console body is exposed. The console cover is pivotally movable between the partially open position and a fully open position wherein the console opening and the sliding member are exposed. The console cover includes at least one follower extending outwardly therefrom, wherein the follower is slidably mounted within the grooves in the storage bin wall.

Abstract: A floor covering or mat for a vehicle is provided, the covering including a hinged flap portion extending from one side, the hinged flap portion in a first position being folded beneath the covering or mat, for storage. In a second position, the hinged flap portion may be folded over onto the top surface of the mat and provide a protective surface and/or display a logo or other information. In a third position, the hinged flap may extend outside of the vehicle and over the door sill and bumper to bridge any gaps and provide a smooth transition for sliding items out of the cargo space. In another aspect, a floor covering for a vehicle is provided, the covering including a hinged flap portion extending from one side, wherein the hinged flap portion may be folded over onto the top surface of the covering and sides of the hinged flap portion folded up and fastened together to form a storage structure.

Abstract: The present invention relates to a slush moldable polymeric composition that is usable in a seamless air bag door skin and methods of making the same. In at least one embodiment, the composition comprises from 35 to 60 wt. percent of a first PVC resin, from 30 to 50 wt. percent of a linear trimellitate plasticizer, and from 1 to 20 wt. percent of an adipate ester plasticizer. The composition is melt processible and is useable to make seamless air bag doors that work successfully in low and high temperatures and have low emissions of VOCs and a low odor grade.

Abstract: A door trim panel including a cover stock, an armrest coupled to the cover stock and having a first density, an upper energy absorber disposed above the armrest and having a second density higher than the first density, and a lower energy absorber disposed below the armrest and having a third density higher than the first density.