Abstract: Porous carpeting for use within vehicles, and methods of making same, are provided. 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 porous thermoformable material may be applied to the porous carpet structure to provide mechanical strength.

Abstract: A method of sewing a decorative seam includes providing a material suitable for receiving stitches, folding a first portion of the material onto a second portion of the material to form a bend, sewing a first stitch to join the first portion to the second portion, the stitch being substantially parallel to the bend and spaced apart therefrom, the first stitch forming a seam, unfolding the material and sewing a second and third stitch into the material such that the second and third stitches are substantially parallel to the seam and arranged such that the second and third stitches are on opposite sides of the seam.

Abstract: In at least one embodiment, the present invention relates to a trim panel for concealing an air bag. The panel comprises a substrate and a cover over the substrate. The cover includes a cover skin. The panel also comprises a tear seam having at least a portion comprising a pattern of alternating residual wall thicknesses in the panel. At least one embodiment of the present invention also relates to a method for making a trim panel for concealing an air bag.

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

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

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: The present invention is directed at an apparatus and method for attaching articles to surfaces, and more particularly to fibrous surfaces, such as carpeting. A polymeric sheet having a peripheral flange including a bonding surface, as well as a raised portion, may be bonded to the fiber surface. The raised portion may then include threads for attachment purposes.

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 console assembly configured for use in a passenger seating area of a vehicle. The console assembly includes a lower console module having a housing extending generally horizontally adjacent a floor of the passenger seating area and an upper console module having a housing disposed adjacent and operatively connected to the lower console module. One or more panels are pivotally connected to the upper console module adjustable between at least a stored position disposed adjacent the upper console module housing and a deployed position wherein the one or more panels form a presentation surface for use in the passenger seating area of the vehicle.

Abstract: In at least one embodiment, the present invention relates to a method for making an automobile interior trim panel, where the method comprises providing a mold tool system comprising a first mold half, a second mold half and a third mold half, introducing a first resin into a first mold cavity to form a trim panel substrate, positioning the first mold half with the trim panel substrate and the third mold half proximate each other to form a second mold cavity generally contouring to the shape of the trim panel and having a first minor cavity extending generally transverse to the exterior surface of the second mold cavity, and introducing a second resin into the second mold cavity to form a cover skin extending over the substrate and having an outer surface and a tab portion extending generally away from the outer surface.

Abstract: A slush moldable composition includes a low density polyethylene resin, propylene-ethylene copolymer, olefin block copolymer, a thermoplastic olefin and silicon oil combination, and an optional pigment. A method for forming a instrument panel skin from the slush moldable composition is provided.

Abstract: Embodiments of the present invention may take the form of a positive retention floor mat system.

Abstract: A trim component such as a bezel for attachment to a trim panel, such as an instrument panel of a vehicle, is disclosed and includes one or more retention tabs for securing the trim component to the trim panel. The retention tabs provide for a plurality of limiting features that help in preventing a non-blunt contactable edge condition from occurring, particularly during an impact between the vehicle and another vehicle or object.

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 headliner assembly is provided for use with a vehicle having an inflatable air bag disposed proximate a roof of the vehicle. The headliner assembly includes a headliner configured to extend underneath the air bag and having a front portion and a rear portion. The headliner assembly further includes a tether for connecting the rear portion of the headliner to a rear portion of the vehicle. The tether is configured to cooperate with the headliner to control deployment of the air bag.

Abstract: In at least certain embodiments, the present invention relates to automobile interior door panel having an insert molded bolster. In at least one embodiment, the automobile interior door panel is made by providing a bolster within a first mold cavity, introducing a first resin into the first mold cavity to form a door panel sub assembly comprising a door panel portion secured to the bolster, with the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster, providing the door panel sub assembly within a second mold cavity, and introducing a second resin less rigid that the first material into the second mold cavity to form a second upper door panel portion over and secured to the first upper door panel portion.

Abstract: A method of making an acoustic insulator includes depositing thermoplastic particulate on a first surface of a base layer. The method further includes heating the particulate such that the particulate at least partially melts and penetrates the first surface of the base layer, thereby increasing density and airflow resistance of the base layer proximate the first surface such that the base layer has an areal mass in the range of 0.1 to 1.0 kg/m2 and an airflow resistance in the range of 300 to 5,000 Nsm?3 proximate the first surface.

Abstract: A trim panel retention system for a vehicle interior includes serviceable trim clips holding trim panel to a base panel in an operating condition. A secondary retaining member extends from the trim panel and passes through a secondary retention opening in the base panel, overlapping the base panel adjacent to the secondary retention opening and spaced from the base panel. If the trim clips become disengaged due a collision and the trim panel separates from the base panel, the secondary retaining member engages the base panel to limit movement of the trim panel.