Abstract: An automotive interior component including an airbag chute having at least one weld bar, and a pre-stressed instrument panel having a substrate layer for bonding to the weld bar. The pre-stressing provides tensile stress at weld bar bonding areas to reduce any deformation visible on an exposed surface of the instrument panel.

Abstract: A method of manufacturing an automotive interior component includes the steps of: providing a mold apparatus comprising a first mold component and a second mold component; providing a substrate; applying a first layer of a soft-touch material to the substrate; applying a second layer of a fabric to one of the first mold component and the second mold component of the mold apparatus; forming a self-skinning foam layer, wherein a first surface of the self-skinning foam layer is configured for bonding to the first layer and a second surface of the self-skinning foam layer is configured for bonding to the second layer; and fastening the substrate, the first layer, the second layer together. Additional methods of manufacturing automotive interior components and automotive interior components are also provided.

Abstract: A method of manufacturing an automotive instrument panel for eliminating distortion in an area of vibration welded air bags comprises: providing a weld fixture including at least one pre-stressor protrusion; placing the at least one pre-stressor protrusion against an instrument panel; generating a force to press the weld fixture against the instrument panel to create compression in a first surface of the instrument panel where the weld fixture contacts the instrument panel and to create tension in a second surface of the instrument panel, the second surface opposite to the first surface; and vibration welding an air bag chute to the instrument panel such that a weld bar of the air bag chute is welded to the second surface of the instrument panel.

Abstract: An injection molded plastic instrument panel P.S.I.R. hidden door milling method including applying a stiff tape, having a hardness greater than a hardness of the plastic instrument panel, to a plastic instrument panel surface to be milled to prevent flexing of the surface during milling. The method may further include milling the surface along a generally width-wise central location of the tape, and removing the tape upon completion of the milling, with the method thereby minimizing burrs along edges of the milled surface. The invention also provides an injection molded plastic instrument panel P.S.I.R. hidden door, and a plastic automotive panel made by method described herein.

Abstract: An automotive Passenger Side Inflatable Restraint (PSIR) hidden door system contained in an automotive instrument panel and a method of scoring the PSIR door system. The system includes forward and rearward doors hingedly connected at first and second hinges, respectively, to a PSIR airbag chute. The system further includes a common tear line of reduced material thickness integrally joining the forward and rearward doors. The common tear line has a substantially non-linear shape with first and second linear ends.

Abstract: An automotive PSIR hidden chute assembly contained behind an automotive instrument panel. The PSIR may include chute forward and rearward doors, first and second chute flanges, and an instrument panel, each constructed of a first hard material, and first and second chute hinges, first and second chute sidewalls and a chute end wall, each constructed of a second tough ductile material, such that the first material and the second material have different thermal expansion properties and different elastic modulus properties.

Abstract: The invention provides for an apparatus and method for attaching a Passenger Side Inflatable Restraint (PSIR) chute. In one embodiment an automotive interior component comprises an automotive instrument panel having an outer surface and an inner surface. The automotive interior component further comprises an automotive PSIR hidden chute assembly contained behind the automotive instrument panel, wherein the PSIR hidden chute assembly has a chute and at least one PSIR door. The chute is connected to the inner surface of the automotive instrument panel. The automotive interior component further comprises a tuning clip connected to the chute and configured to engage the PSIR door. Engagement of the tuning clip to the PSIR door reduces deflection of the automotive instrument panel visible on the outer surface by biasing the PSIR door upward.

Abstract: A method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes forming at laminate preform, injection molding a substrate layer behind the laminate preform to form a molded automotive interior panel, and forming an opening in the molded automotive interior panel. The method further includes post embossing the molded automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the molded automotive interior panel and a mating subcomponent installed in the opening, thereby producing a tight bezel fit between the molded automotive interior panel and the mating subcomponent installed in the opening. Alternatively, the method includes utilizing a vacuum wrapped automotive interior panel with the embossing step described above. The invention also provides for an automotive interior panel including a tight bezel fit between the panel and mating subcomponents, formed by the aforementioned methods.

Abstract: A passenger airbag module removably connectable to an automotive interior component. The passenger airbag module may include a front bracket engageable with an automotive interior component and a rear connector having a detent or an aperture. A rear bracket may be removably connectable with the rear connector by an aperture or detent for respectively receiving or insertion into the detent or aperture of the rear connector. The rear bracket may be further configured to engage the automotive interior component.

Abstract: The invention provides for an apparatus and method for attaching a Passenger Side Inflatable Restraint (PSIR) chute. In one embodiment an automotive interior component comprises an automotive instrument panel having an outer surface and an inner surface. The automotive interior component further comprises an automotive PSIR hidden chute assembly contained behind the automotive instrument panel, wherein the PSIR hidden chute assembly has a chute and at least one PSIR door. The chute is connected to the inner surface of the automotive instrument panel. The automotive interior component further comprises a tuning clip connected to the chute and configured to engage the PSIR door. Engagement of the tuning clip to the PSIR door reduces deflection of the automotive instrument panel visible on the outer surface by biasing the PSIR door upward.

Abstract: The invention provides for a multi-layer automotive interior component and method of making the same. The multi-layer automotive interior component comprises a skin layer having an exterior portion and an underside portion, where the exterior portion is visible. The multi-layer automotive interior component further comprises a foam dam formed on the underside portion of the skin layer, a cantilevered skin portion extending from the foam dam, a substrate disposed opposite the underside portion of the skin layer, and a foam layer between the substrate and the underside portion of the skin layer. The foam layer is limited by the foam dam, and the foam layer is substantially uniform.

Abstract: The invention provides for an automotive interior component and method of making the same. The automotive interior component comprises a dock for receiving an object, a holder for receiving the dock and configured to movably store the dock, and a light source operatively connected to the dock. The light source provides continuous illumination of the dock as the dock moves from the holder to a deployed position, allowing ease of visible location and augmenting visual appeal of an automotive interior.

Abstract: A method of producing tight bezel fits between automotive interior panels and their mating subcomponents. The method includes forming at laminate preform, injection molding a substrate layer behind the laminate preform to form a molded automotive interior panel, and forming an opening in the molded automotive interior panel. The method further includes post embossing the molded automotive interior panel adjacent a perimeter of the opening to produce an embossed interface between the molded automotive interior panel and a mating subcomponent installed in the opening, thereby producing a tight bezel fit between the molded automotive interior panel and the mating subcomponent installed in the opening. Alternatively, the method includes utilizing a vacuum wrapped automotive interior panel with the embossing step described above. The invention also provides for an automotive interior panel including a tight bezel fit between the panel and mating subcomponents, formed by the aforementioned methods.

Abstract: This invention relates to the field of airbag covers such as are used in the interior of vehicles, and more specifically to an airbag cover having a novel tear seam. The tear seam is adapted to be located over a pair of deployment doors which are located behind the airbag cover. According to one embodiment, the tear seam includes a transverse segment having a width adapted to extend beyond the perimeter of the underlying deployment door. The tear seem also includes a first end segment and a second end segment. The transverse segment extends between and intersects each of the first end segment and the second end segment at locations distal from the perimeter of the underlying airbag door. The first end segment and second end segment each include at least one convex segment proximal the intersection of the first end segment with the transverse segment. Each convex segment is further adapted to be substantially perpendicular to a deployment induced stress pattern in the airbag cover.

Abstract: A method of molding a composite structure of a polymeric preformed skin with tightly radiused features and a polymeric foam body is provided. The method includes providing a mold cavity having a first edge; placing the preformed skin in the mold cavity with a preformed first edge of the preformed skin adjacent to the first edge of the mold cavity; heating the preformed skin adjacent the first edge; exposing the first edge to a vacuum to reform the preformed skin first edge to be adjacent the mold cavity first edge and injecting a foam polymeric material into the mold.

Abstract: An apparatus for molding a polymeric multiform skin membrane is provided. The molding apparatus includes a rotatable heated mold envelope having an opening. Additionally the mold envelope has channel members which generally extend lateral of the opening. A feed-stock bucket is provided for holding polymeric work stock. The bucket is moved by a carriage in a direction generally parallel with the channel members of the mold envelope with a first lateral position for loading and a second position closing the opening of the mold envelope. Selectively actuatable clamps are provided for securing the bucket with the mold envelope.

Abstract: A multi element moving vacuum chamber (MEMVC) for rotational casting includes a mold having a predefined shape and an axis of rotation, and a box containing casting material. The MEMVC further includes a first vacuum element mounted to an outer mold surface and a second vacuum element mounted to an outer box surface. The mold and the box are detachably engageable with each other to define an engaged configuration in which air present in an enclosed area defined by the outer mold surface and an inner surface of the first vacuum element, by an inner mold surface and an inner box surface, and by the outer box surface and an inner surface of the second vacuum element, is removed to create a vacuum. Alternatively, the mold and/or the box may be constructed with vacuum loading capability, thereby eliminating the need for the first and/or the second vacuum elements.