Abstract: Injection molding techniques are utilized to form complex switches without removal from a molding machine. Multi-shot molding techniques are utilized, as are rotational indexing molding machines. Springs are formed of resilient elastomeric material. Contacts may be inserted into the mold prior to injection of the plastic, or can be formed from conductive plastic. The present method reduces the cost and complexity of forming electrical components.

Abstract: A modular headliner includes a central lamp component with an upper and lower lamp components. The upper and lower lamp components snap together on each side of the headliner. This allows the lamp to be mounted into the vehicle with the lamp already assembled. The upper lamp component is provided with a pair of spaced adhesive tape strips. The adhesive tape strips wet out on a support surface in the vehicle ceiling, securing the upper component to the vehicle ceiling. In this way, there is no complex alignment necessary between the components of the lamp and structure on the vehicle ceiling. Instead, the upper component of the lamp merely attaches itself to the ceiling wherever it may be in the individual vehicle, utilizing the individual headliner. Further, the lower component is attached to the upper component through a yieldable connection. In this way, the lower component can be removed from the upper component after the headliner has been assembled into the vehicle.

Abstract: A remotely controlled electrical accessory system for starting an engine of a vehicle and actuating a garage door opener attached to a garage door. The system includes a first transmitter for producing an engine ignition signal and a second transmitter for producing a garage door opener actuation signal. A receiver starts the engine of the vehicle and energizes the second transmitter to produce the garage door opener actuation signal in response to the engine ignition signal. In a preferred embodiment, the system includes a proximity sensor attached to the vehicle for producing a gating signal in response to a closed garage door. Preferably, the receiver starts the engine of the vehicle in response to the engine ignition signal and energizes the second transmitter to produce the garage door opener actuation signal in response to the engine ignition signal and the gating signal.

Abstract: A unique flexible hinge member for an instrument panel airbag is formed of a flexible plastic. The flexible hinge member is secured to the under surface of the instrument panel by a welding technique. The instrument panel is formed with a tear seam on its under surface, but no tear seam on its under surface. In one embodiment, the tear seam is h-shaped and two flexible hinge portions are utilized. In another embodiment, the tear seam is u-shaped and a single flexible hinge member is utilized.

Abstract: An electroluminescent display includes a plurality of generally parallel outer electrodes and a plurality of generally parallel inner electrodes perpendicular to the outer electrodes. A plurality of generally parallel reflective surfaces are formed parallel to the outer electrodes or the inner electrodes to selectively provide a mirrored appearance when the electroluminescent display is not activated. A variable transmissive device, such as an electrochromic dimmer, is positioned in front of the ELD to selectively dim the light emitted from the ELD.

Abstract: A mold for assembling and forming a wire harness preferably includes wire supports extending into a continuous trough which forms a main trunk and a plurality of branches extending from the main trunk. A port introduces a generally liquid sheath material into the trough of the mold. Wires are routed on the wire supports along the main trunk and branches of the trough in the mold. The sheath material is then introduced into the mold and cures around and among the plurality of wires.

Abstract: An assembly mounts the rear stop lamp and the rear cargo lamp in a rear cargo door of a vehicle at adjacent locations. A single control board mounts both lamps. The boards can have different configurations. However, in each embodiment a single board preferably provides power and control signals to the stop lamp and the cargo lamp. In this way, the number of parts necessary for providing the lamps are reduced. In addition, since the lamps are mounted adjacent to each other, a single space may be utilized for both lamps. Various types of lamps may be utilized within the scope of this invention.

Abstract: A vehicular rearview mirror assembly includes a mirror housing, a mirror, and a light assembly. The light assembly is supported within a channel in the mirror housing for slidable movement from a retracted position behind the mirror to an extended position adjacent the mirror. The light assembly includes a light housing and a light emitting device adapted to provide sufficient light to illuminate the face of a user. The light assembly is operatively connected to a switch which prevents the light emitting device from operating unless the vehicle transmission is in a park setting.

Abstract: A removable light is mounted into an exterior mirror on a vehicle. The light selectively provides illumination when mounted in the mirror. When removed from the mirror, the light provides an optional flashlight accessory.

Abstract: An improved apparatus and method for securing a wire harness to a vehicle trim panel includes the use of an inventive holding clip. The clip has a secured portion which is fixed to the underlying trim panel. A retaining portion is biased against the trim panel, and wires are received in a holding portion between the secured portion and the retaining portion. The clip also includes an entry portion spaced away from the retaining portion which facilitates the movement of the wire under the entry portion to bias the retaining portion away from the trim panel and allows movement of a wire into the holding portion. In a first preferred method, the wires are assembled by first attaching the clips to the trim panel and then routing the wires into the holding portion. In a second preferred method, the wires are routed into the clips prior to the clips being secured to the trim panel. The clips are then secured to the trim panel and at the same time the wires are captured on the trim panel.

Abstract: A programmable transmitter includes a receiver for receiving a coded signal at a desired frequency. The code is stored in memory during a learning mode and is then retransmitted sequentially at a plurality of frequencies, including said desired frequency. During this time, the operator observes the device to be operated and indicates to the transmitter when the controlled device performs the desired function, i.e., when the desired frequency is transmitted. At that time, the operator presses a button on the transmitter, and the transmitter stores the most recently transmitted frequency.

Abstract: A vehicle switching system includes a transmitter generating signals based upon activation of one of a plurality of switches. Switches mounted on vehicle components in the vehicle are each associated with a predetermined vehicle function. A receiver in the vehicle receives the signal from the transmitter and activates the predetermined vehicle function.

Abstract: A seat system for a passenger vehicle includes a foldable rear seat and a foldable front seat. The rear seat includes a removable seat bottom and a forwardly folding seat back. An approximately horizontal rear support surface is formed by a surface of the rear seat back when the rear seat back is folded forward. The front seat includes a seat bottom and a forwardly folding seat back. An approximately horizontal front support surface is formed by a surface of the front seat back when the front seat back is folded forward. An extended support surface is formed by the rear support surface and the front support surface. If desired, the front seat can be mounted on a track assembly so that the front and rear support surfaces can be placed in close proximity to each other. If desired, a workstation can be formed in the front support surface.

Abstract: A speaker support bar supports a pair of speakers above a vehicle headliner. The speaker support bar is positioned vertically above the headliner, and thus the uniform appearance of the headliner is preserved. The speaker support bar extends between lateral support ends which transfer the weight of the speakers to the headliner over a wide area, and near the vehicle frame. Thus, the headliner is able to support the weight of the speakers. The invention also facilitates the pre-assembly of the headliner and its sound system prior to attachment of the headliner to the vehicle.

Abstract: A multi-functional electronic actuator for actuating multiple independent systems on an automotive vehicle includes a magnet assembly, a rotor mounted within the magnet assembly having an armature and a shaft that rotates when the armature is energized, a device for translating the rotor with respect to the magnet assembly, and devices for actuating a first independent system on the automotive vehicle utilizing the rotational motion of the shaft and for actuating a second independent system on the automotive vehicle utilizing the translation of the rotor shaft with respect to the magnet assembly. Two methods for translating the rotor with respect to the magnet assembly are described as well as various linkages that may be used to actuate the independent systems on the automotive vehicle.

Abstract: An antenna for an RF transmitter is incorporated into the front door pillar trim member in a vehicle cab. This location for the antenna maximizes the transmission characteristics of the antenna. A switch and a transmitter are also preferably mounted on the trim member. The switch and transmitter are incorporated into a garage door opening system. The antenna is ideally positioned to transmit a signal to the garage door opener.

Abstract: A mold for forming a wire harness includes a trough having a concave surface. A plurality of wire supports extend into the trough for supporting a plurality of wires in the trough and spacing the wires away from the concave surface. A polymer sheath material is introduced into the trough, thereby encasing the wires.

Abstract: A mirror housing is formed of two colors in a two-stage molding process. An inlay of the first color is inserted into a mold, and plastic of a second color is molded to surround the inlay. In this way, a two-toned mirror housing is formed without the necessity of painting or masking.

Abstract: A wire harness for use on contoured, mounting surface includes individual wires bundled together. In an effort to protect these wires from mechanical wear, vibration, and water the wire harness is encased in foam. The foam is molded about the wire harness so that is surrounds the harness in the shape of the mounting surface. The foamed-in wire harness may have an elastic memory, so that it can be bent and resiliently recover to its molded shape.