Abstract: Decorative or protective appliqués' or trim panels having a wide range of decorative patterns may be formed by injection molding a backing layer behind and a transparent outer layer on the top surface of a thin foil, film, fabric or veneer. Use of multiple layers of decorative film, transparent plastic and colored/opaque plastic is also disclosed to provide distinguishing visual effects. The appliqués and trim panels may be backlighted or edge-lighted selectively by providing a light source behind or optically coupled to a runner molded as part of the transparent outer layer.

Abstract: A relatively thin printed LED backlight device with an integral diffuser may be integrated into an interior trim component using a molding process, such as injection molding, compression molding and reaction injection molding. The display portion may be placed behind a textile surface or molded grille or may form a portion of the outer surface of the trim component to provide light to low light areas of the vehicle. Electronic circuitry and components may be printed on to the substrate of the device as part of an in-line continuous process at the molding station to allow low inventory and customization of each backlight device.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: The present invention relates to a slush moldable polymeric composition for forming a skin useable in interior trim components and methods of making the same. In at least one embodiment, the composition comprises a) from 50 to 99 wt. percent urethane elastomer, b) from 0.1 to 15 wt. percent propylene copolymer, c) from 0.1 to 25 wt. percent olefin modified thermoplastic, such as SEBS, and d) from 0.1 to 30 wight percent olefinic block copolymer, wherein the polymeric composition is slush moldable and vacuum formable. The modifiers include an olefin block copolymer (OBC) having a variable distribution of block lengths. The OBC is present in an amount from 0.1% to 30% of the total composition. The haptics of the polymeric composition is tunable by adjusting the amounts of the modifiers.

Abstract: A vehicle instrument panel skin comprises residues of a thermoplastic urethane elastomer and a propylene-ethylene copolymer. The thermoplastic urethane elastomer includes a polyol, an organic diisocyanate, an optional chain extender, and an optional hindered amine light stabilizer and a benzotriazole ultraviolet stabilizing agent. A method for forming the instrument panel skin is also provided.

Abstract: A molding process for forming a grained trim panel having improved haptics is provided. A relatively soft ungrained skin may be placed into a relatively cool textured compression mold and a heated web of mixed synthetic and natural fibers placed onto the skin. The mold may be closed and the web compressed at about 100-300 N/square centimeter causing a panel to be formed in a single process that includes an integrally formed texture and a substrate layer.

Abstract: In at least one embodiment, the present invention relates an airbag assembly comprising a panel having a tear seam forming at least one airbag door, and a door chute assembly comprising a laterally extending flange connected to the panel proximate the airbag door. The door chute assembly includes a chute depending from the flange away from the panel and the chute has at least one opening. The airbag assembly further comprises a door panel assembly including at least one door panel disposed within the chute and connected to the airbag door. The door panel has a downwardly depending flange having at least one projection extending laterally through the at least one opening of the chute. The airbag assembly further comprises an inflatable airbag mounted on the door chute.

Abstract: This invention relates to a console that is adapted to be located between first and second seats in a vehicle, the console having a base including a guide surface; and an armrest supported on the guide surface for movement relative to the base in a first direction and a second direction that is different from the first direction.

Abstract: A relatively thin printed LED backlight device with an integral diffuser may be integrated into an interior trim component using a molding process, such as injection molding, compression molding and reaction injection molding. The display portion may be placed behind a textile surface or molded grille or may form a portion of the outer surface of the trim component to provide light to low light areas of the vehicle. Electronic circuitry and components may be printed on to the substrate of the device as part of an in-line continuous process at the molding station to allow low inventory and customization of each backlight device.

Abstract: A visor vanity including a visor body for a vehicle having an electrical system is provided. The visor body includes a visor mirror, at least one light source, a switch, a regulator circuit and a timer. The switch causes at least one energy source that is independent of the electrical system of the vehicle to generate a first voltage signal. The regulator circuit is operably coupled to the switch and to the energy source for transmitting a second voltage signal in response to the first voltage signal so that the light source receives the second voltage signal. The timer is powered by the energy source for causing the regulator circuit to disable the operation of transmitting the second voltage signal in response to the timer achieving a predetermined count value.

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: A floor mat having a first surface, a second surface disposed opposite the first surface; and a V-shaped retention feature. The V-shaped retention feature extends from the second surface and has first and second ramp surfaces disposed at an angle relative to the second surface.

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 hollow structural member including a top wall having an inner surface and a substantially planar outer surface. A bottom wall opposes the top wall so as to define a void therebetween and has at least one bulwark formed therein. Each bulwark has a leading face which is joined to the inner surface of the top wall to form a double-walled bulwark bridging the void. The double-walled bulwark has opposing walls and a reinforcing member that is encapsulated thereby. A process for producing a hollow structural member includes placing a parison between two mold halves before bringing together the first and second mold halves. A movable blade is positioned therein. When in the closed position, movable blade is extended into a cavity defined by the first and second mold halves to form the bulwark in the second portion of the parison to be formed into a bottom wall.

Abstract: A headliner and bracket cooperate to define a trim edge around a vehicle sunroof. The bracket may include a lip that wraps around an edge of the headliner and trim associated with the headliner.

Abstract: A method of making a sound insulating layered composite structure by roll coating a padding layer with an emulsion which may then be solidified to form a layer disposed over at least a portion of the padding layer. The emulsion may be applied using various devices and applied at thicknesses as to provide the capability to tune the acoustic performance of the composite.

Abstract: A three piece fastener is provided for attaching two layers, e.g. a floor mat for a vehicle to a floor carpet which may then stabilize the mat relative to the carpeting. The three components may connect together through a combination of mechanical connections to provide a relatively simple and cost effective solution to floor mat retention.

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: 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: A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.