Abstract: A door trim speaker grille with an electroluminescent lamp for use with an audio speaker of a vehicle. The electroluminescent lamp is positioned for emitting visible light through sound passages in the speaker grille. In certain embodiments of the invention, the electroluminescent lamp may be integrally molded with the speaker grille. One method of forming the door trim speaker grille is by an injection molding process that places the electroluminescent lamp as an insert in the mold cavity.

Abstract: An interior trim panel for a vehicle door is provided according to alternative methods. The interior trim panel includes a bolster to which a polyurethane skin is molded by a spraying operation. Expanded polyurethane foam is sprayed over the polyurethane skin and a backing panel is either integrally formed or assembled to the polyurethane foam layer.

Abstract: An attachment member for attaching a sun visor to a vehicle support structure includes a base portion that is configured to face a first side of the support structure, and a projecting portion having first and second ends. The first end is attached to the base portion, and the second end is free and extends to a location proximate the base portion. The projecting portion further has first and second spaced apart attachment features disposed proximate the first and second ends, respectively. The attachment features are engageable with a second side of the support structure. Moreover, the second end of the projecting portion is configured to flex when the projecting portion is inserted into an opening of the support structure to allow the attachment features to pass through the opening and engage the second side of the support structure.

Abstract: A portable tray for use at multiple locations of the interior of a vehicle includes a body adapted to be operatively supported to the interior of the vehicle and defining at least one substantially planar work surface. The tray also includes a support mechanism connected to the body and adapted to removably support the body to structural components of the interior of the vehicle such that the tray can be manually moved and used at various locations within the interior of the vehicle.

Abstract: A structural rail system 10 for supporting an overhead console 12 in relation to a roof bow 13 within a vehicle. A pair of rail members 14, 16 are spaced apart and extend longitudinally. One or more brackets 18, 20, 22, 24 are oriented laterally in relation to the pair of rail members 14, 16. Accessories 26 are attached to the brackets 18, 20, 22, 24 and are housed within the console 12.

Abstract: A method of manufacturing an airbag assembly and a trim component for vehicle including the step of providing a first mold structure having a first surface formed therein, a second mold structure having a second surface formed therein and a third mold structure having a third surface formed therein. The first mold structure and the second mold structure are positioned to define a first cavity. A first material is introduced into the first cavity to form a substrate. The substrate and the third mold structure are positioned to define a second cavity. A second material is introduced into the second cavity to form at least one of a portion of an airbag assembly and an outer layer overmolded onto the substrate. Additionally, a scrim material may be disposed within the second cavity to produce a hinge having an embedded layer of scrim material.

Abstract: An airbag chute assembly for a vehicle. The airbag chute assembly includes a chute portion, an inflator housing, and a coupling member that facilitates coupling and decoupling of the inflator housing.

Abstract: A blow molded structure comprising a body made out of a first polymeric material and an integrally molded, coextruded living hinge made out of a second, more flexible polymeric material. A method of making a blow molded article having a coextruded living hinge.

Abstract: The present invention relates to a trim panel assembly for a vehicle having integrated energy management characteristics and method of manufacture. The trim panel assembly comprises a panel made of a first material having a first panel surface and a second panel surface, a skin covering at least a portion of the first panel surface of the panel, with the skin being made of a second material less rigid then the first material, and a rib depending from the second panel surface away from the skin. The rib has at least a first portion being made of the second material.

Abstract: A trim panel assembly having a first housing, a second housing, and a pivotal light mechanism configured to swivel relative to the first and second housings.

Abstract: An interior trim panel for a vehicle door is provided according to alternative methods. The interior trim panel includes a bolster to which a polyurethane skin is molded by a spraying operation. Expanded polyurethane foam is sprayed over the polyurethane skin and a backing panel is either integrally formed or assembled to the polyurethane foam layer.

Abstract: A removable storage module assembly configured for securement to the headliner in a passenger compartment of a vehicle. The headliner includes a storage module receiving area formed therein having a securement portion disposed proximate the receiving area. A storage module having a housing, a fastener associated with the housing configured to engage the securement portion and a storage area defined in the housing is removably positioned in the storage module receiving area.

Abstract: A method and apparatus for forming an interior component part having a relatively rigid substrate portion and a padded portion. The molding tool used to form the substrate portion includes a first mold part and a second mold part that form a substrate molding cavity into which a thermoplastic olefin is injected. The padded portion is formed by the first mold part and a third mold part that define a pad forming cavity. A mixture of a thermoplastic elastomer and a blowing agent is injected into the pad forming cavity. The expanded blown elastomer is enveloped within a skin formed when the blown elastomer contacts a cooled mold surface.

Abstract: A center stack for an instrument panel of a motor vehicle. The center stack includes a front plate having an exposed surface with a first surface finish and a back plate having a visible portion uncovered by the front plate. The front plate has at least one opening extending through the exposed surface for accessing at least one operational feature of the motor vehicle. The visible portion of the back plate has a second surface finish that differs from the first surface finish of the front plate. The back plate may include a flex joint that permits the visible portion of the back plate to move relative to an adjacent non-visible portion covered by the front plate.

Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining shoddy bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a bituminous mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the shoddy bottom layer and the scrim top layer.

Abstract: This dual use injection molding tool comprises injection molding tool with techniques for both low pressure and high pressure injection molding for injection of material into a bolster and a lifter. In the retracted, non-functional position, this tool is capable of low pressure injection molding techniques. In the extended, functional position, this tool is capable of high pressure injection molding techniques.

Abstract: Dual function console lighting with integrated switching includes a lamp housing held by a retainer within a bezel secured to a vehicle interior. The lamp housing includes eccentrically positioned collinear pivot arms relative to a central longitudinal axis of a lamp positioned within the housing. The pivot arms engage the retainer to hold the lamp housing within the retainer while allowing the lamp housing to pivot relative to the plane of the retainer. The retainer is rotatably held within the bezel by a plurality of snap features spaced around its circumference, allowing the lamp housing and retainer to rotate. A latching mechanism holds the lamp housing in a retracted position with a lens of the housing preferably substantially flush relative to immediately surrounding portions of the bezel. A spring provides a force to pivot the housing about the pivot arms to a second position when the latch is released.

Abstract: In at least one embodiment, the present invention relates to a modular vehicle interior component system which comprises a base having a channel defined at least in part by a latching lip, a vehicle interior component, and a release latch mechanism for slidably and releasably securing the component to the base.

Abstract: A system for vehicle interior electrical power distribution includes an electrical power track assembly having at least one electrical power strip and at least one electrical ground strip, and an electrical connector assembly slidable in the track assembly. The electrical connector assembly has a first set of electrical contacts and a second set of electrical contacts. The first set of electrical contacts are configured to maintain electrical connection with respective ones of the at least one electrical power strip and the at least one electrical ground strip during sliding such that the slidable connector assembly provides electrical power to respective ones of the second set of electrical contacts, and the second set of electrical contacts are configured to electrically couple to and provide electrical power to at least one removable electrical accessory that is installed to the slidable connector assembly.

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 comprising a window portion communicating with an angled channel portion. 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.