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: A visor support is disclosed with a support arm and a rotation control member. The support arm is adapted to support a visor body and has a first end adapted to be mounted in a vehicle. The support arm has a tapered portion near a second end of the support arm and a ring proximate to the tapered portion. The rotation control member has at least one wall with at least one aperture therein. The rotation control member has a tapered receptacle aligned with the at least one aperture. The rotation control member is rotatable about a linear axis of the support arm such that the tapered portion and the tapered receptacle cooperate to prevent rotation of the support arm absent an external force. The ring cooperates with the rotation control block to at least retain the support arm within the rotation control member.

Abstract: An apparatus and method of producing plastic articles comprising preheating a metal mold having a mold contour using infrared heating elements formed to match said mold contour to establish a casting temperature, casting plastic material onto the preheated metal mold surface, fusing the plastic using infrared energy, cooling the metal mold using the change of phase or state of a cooling material and removing the cast plastic article from said metal mold.

Abstract: Acoustically absorptive carpeting includes a primary layer of fibrous material with yarn tufts extending outwardly therefrom and a secondary layer of thermoplastic material that forms a carpet backing. The carpet backing is rendered porous. A substrate of porous material is attached to the carpet backing. The substrate includes a layer of fine fibrous material attached to a layer of coarse fibrous material. The layers of fine and coarse fibrous material each have respective different acoustic impedances. The layer of coarse fibrous material has fibers in an open, loose configuration. The carpet backing is bonded to the layer of coarse fibrous material with a thermoplastic adhesive material such that the thermoplastic adhesive material encapsulates individual fibers of the layer of coarse fibrous material without extending therebetween.

Abstract: A lamp assembly includes a bezel having a lamp receiving section and an integrated attachment section. The integrated attachment section has one or more outwardly directed extensions for attaching the lamp assembly to the interior component by rotating the bezel into a receiving aperture. A lamp housing is disposed within the lamp receiving assembly. Finally, the lamp assembly includes a light source positioned within the lamp housing for projecting light along a light path.

Abstract: A vehicle seat assembly is disclosed for use in a vehicle having a removable stowable panel. The seat includes a seat body having a seat bottom and a reclinable seat back. A trim component is supported on the seat body and hangs in a downward direction behind the seat body and is free to move in a direction rearward of the seat body. A receiving member is supported by the trim component such that the receiving member is disposed below a bottom portion of the seat back and moves rearward as the trim component moves rearward. The trim component and the receiving member permit the end of the removable panel to move partially away from the seat body as the seat is reclined when the removable panel is stowed on the vehicle seat assembly.

Abstract: Disclosed is a radio bin spacer that allows for a standard sized radio to be mounting in an instrument panel mounting area sized for the larger style radio.

Abstract: A load floor system for use with a vehicle seat having a seat bottom and a seat back connected to the seat bottom includes a load floor member adapted for pivotal connection to the seat back and configured to move between a stowed position and a deployed position when the load floor member is pivotally connected to the seat back. The load floor member may be substantially horizontal and disposed above and spaced apart from a floor surface of the vehicle when in the deployed position. A support member supports the load floor member when the load floor member is in the deployed position.

Abstract: A pocketed panel assembly for a vehicle door is disclosed herein. The pocketed panel assembly includes a trim panel, a partial pocket structure, and a living hinge. The trim panel has a pivotal edge, and the partial pocket structure also has a pivotal edge. The living hinge integrally joins the pivotal edge of the trim panel to the pivotal edge of the partial pocket structure. In such a configuration, the partial pocket structure can be rotated about the living hinge and substantially abutted against the trim panel so as to form an open pocket on the trim panel.

Abstract: A height adjustable armrest assembly for use with a vehicle may include a support member adapted for connection to a vehicle body. A linkage may be supported by the support member and an armrest member may be supported by the linkage. The linkage may be configured to move the armrest member between a lowered position and a raised position such that the angular orientation between the support member and the armrest member when the armrest member is in the raised position is substantially the same as when the armrest member is in the lowered position.

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 provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: The present invention provides for an improved trim part, such as an automotive handle, with a soft feel, for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, an automotive handle includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. A handle cover is molded to at least a portion of the substrate by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the handle with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the handle.

Abstract: A vehicle floor covering includes a layer of material having a plurality of apertures formed therethrough, and a plurality of decorative articles releasably secured within the respective plurality of apertures. The decorative articles are configured to alter the aesthetic appearance of the floor covering. Each aperture includes a peripheral edge and each decorative article includes a peripheral edge having a groove configured to releasably receive the peripheral edge of a respective aperture. Other decorative articles may be secured to other portions of a vehicle interior to alter the aesthetic appearance of vehicle interior.

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

Abstract: A load bearing cover assembly for use with a vehicle having a floor, having a storage compartment. The load bearing cover assembly includes a cover member having a first side and a second side opposite the first side, the cover member being substantially rigid and adapted for connection to the vehicle such that the cover member may be positioned to at least partially cover the storage compartment, a first support rib may be attached to the first side of the cover member; and a second support rib may be attached to the second side of the cover member, the first support rib and the second support rib each having an aperture for selectively attaching a cargo securing member.

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 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: A mold assembly having a first mold portion with a first cavity having a retention groove. A second mold portion associated with the first mold portion and configured to come together therewith. The second mold portion has a second cavity. The second cavity and the first cavity form a first substrate compartment. A third mold portion is associated with the first mold portion and configured to come together therewith. The third mold portion has a third cavity having a shut-off member. The third cavity and the first cavity form a first over-mold compartment when the first and third mold portions come together. The shut-off member projects from the third cavity surface to impinge on a surface of a component formed by the first substrate compartment. The first retention groove mirrors the shut-off member and is aligned therewith when the first and third cavities form the first over-mold compartment.

Abstract: An overhead console assembly for a vehicle includes accessory module compartments selectively positioned and removably secured to the overhead console for storing materials within the compartments. The overhead console includes a first console housing disposed to an miner surface of a structural member of a headliner assembly on a roofline of a vehicle, a second console housing disposed on the structural member of the headliner spaced apart from the first console housing and a center console housing disposed between the first and second console housings. At least one accessory module is removably secured to the center console housing. The at least one accessory module includes a housing, a storage area defined within the housing to retain materials stored within, and at least one securing member coupling the at least one module to a securement surface provided on the center console housing.