Abstract: An article including a panel structure mountable in an automobile vehicle to form a part of the vehicle interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a first composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a second composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer. The layered composite structure is united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer.

Abstract: An article including a panel structure mountable in an automobile vehicle to form a part of the vehicle interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer. The layered composite structure is united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer.

Abstract: A cross car duct for use in an instrument panel assembly of an automotive vehicle includes an upper beam of one piece molded plastic extending longitudinally between opposing A-pillars of the vehicle. The cross car duct also includes a lower beam of one piece molded plastic attached to the upper beam and extending longitudinally between the A-pillars. A magnesium steering column support for supporting conventional steering components on the cross car duct is fixedly secured to the upper beam. The upper beam includes a plurality of air ducts and the lower beam includes a plurality of air openings aligned with the air ducts for passing air through the beams. The lower beam also includes a housing for supporting an HVAC module. The cross car duct further includes a plurality of integrated mode doors and actuators operatively connected to the housing of the lower beam for actuation between an open position spaced from the air openings and a closed position covering the air openings in the lower beam.

Abstract: A panel structure is mountable in a vehicle to form a part of the interior thereof in concealing relation to a secondary restraint system. The novel panel structure of this invention includes a layered composite structure and a reinforcing substrate having a door structure movable through the layered composite structure upon the operation of the secondary restraint system. The layered composite structure includes an outer layer and an inner layer adhered to the outer layer, the inner layer including a seam-defining structure. In one embodiment, the seam-defining structure is a narrow elongated structure configured to define an exteriorly invisible tear seam generally corresponding with portions of an outline of the door structure, and the inner layer has a reduced thickness portion along the exteriorly invisible tear seam by virtue of the presence of the narrow elongated structure.

Abstract: A panel structure is mountable in a vehicle to form a part of the interior thereof in concealing relation to a secondary restraint system. The novel panel structure of this invention includes a layered composite structure and a reinforcing substrate having a door structure movable through the layered composite structure upon the operation of the secondary restraint system. The layered composite structure includes an outer layer and an inner layer adhered to the outer layer, the inner layer including a seam-defining structure. In one embodiment, the seam-defining structure is a narrow elongated structure configured to define an exteriorly invisible tear seam generally corresponding with portions of an outline of the door structure, and the inner layer has a reduced thickness portion along the exteriorly invisible tear seam by virtue of the presence of the narrow elongated structure.

Abstract: An article including a panel-like structure mountable in an automobile vehicle to form a part of the vehicle interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer.

Abstract: An article including a panel-like structure mountable in an automobile vehicle to form a part of the interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer. The inner layer with the outer layer chemically bonded thereto is united with the rigid substrate so that the rigid substrate serves to reinforce the outer layer.

Abstract: An automotive seating assembly (10) having a seat cushion (22) which is selectively stowed within a floor (14) of a vehicle. A rear support bracket defines a rear portion (36) of the seat cushion (22) and moves between a use position supporting the rear portion (30) above the floor (14) and a stowed position disposed within the floor (14). A front beam (40) defines a front portion (32) of the seat cushion (22) and moves between a use position supporting the front portion (32) above the floor (14) and a stowed position disposed within the floor (14). A flexible mesh material (56) is secured to the front beam (40) at one end (58) and is secured to the rear support bracket (36) at the other end (60) to define a seating portion (34) of the seat cushion (22). The mesh material (56) moves between a support position extending between the front (32) and rear (34) portions above the floor (14) and a retracted position collapsed below the floor (14).

Abstract: A clip assembly presents indicia on an interior panel of a vehicle. The clip assembly has a face plate having indicia thereon and a base for mounting the clip assembly to the interior panel. The face plate has at least two barbed posts. The base has a contour which is asymmetrical in at least one direction. The base engages with a complementarily shaped recess on the interior panel such that the base is received therein in only one orientation. The base has at least two complementary apertures receiving the posts. The apertures and the posts are constructed and arranged such that the face plate engages the base through the interior panel in only one orientation relative thereto, enabling the face plate to be attached to the interior panel presenting the indicia in a predetermined readable orientation.

Abstract: A cargo net assembly which may be installed and removed from between a pair of seats within an automotive vehicle. The net assembly includes a substantially rectangular interwoven mesh net. A retainer is mounted to each corner of the net for supporting the net within the vehicle. A mounting frame is secured to an interior of the vehicle and includes an aperture with an insertion section and a restraint section for receiving the retainer. The net assembly is characterized by a pair of locking tabs disposed on the mounting frame for retaining the retainer in the restraint section. The retainer also includes a clamping portion for anchoring the retainer to the corners of the net and fastening portion extending from the clamping portion for mounting the retainer to the vehicle. The clamping portion includes two interconnected sections with the corner of the net sandwiched between the sections.

Abstract: A panel structure mountable in a vehicle to form a part of the interior thereof, and a process for making the same. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed thermoplastic polyurethane composition and a light-stable, blocked, heat-activated diisocyanate onto a mold surface and thereafter drying the composition. Next, a rapidly reacting composition is sprayed onto an inner surface of the outer layer while the outer layer is retained on the mold surface to form a polyurethane elastomer inner layer that is interfacially chemical bonded to the outer layer. The inner layer with the outer layer interfacially chemically bonded thereto is then united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer.

Abstract: An automotive seat assembly is provided with an integrated side impact airbag. The seat assembly comprises a seat cushion and a seat back mounted to the seat cushion. A seat cushion trim cover material covers the seat cushion and a seat back trim a cover material covers the seat back. The seat assembly is characterized by a tear seam integrally formed within a bolster section of the seat back trim cover material. The tear seam defines a frangible line of weakness within the trim cover material wherein the airbag will tear through the tear seam when the airbag is deployed and inflated to a position outside of the seat assembly. The subject invention also includes a manufacturing apparatus for forming the tear seam in the trim cover material. The apparatus comprises a template (48) supporting the trim cover material (28). A C-shaped raised ridge (50) extends upwardly from the template to abut the inside surface of the trim cover material (28).

Abstract: A modular headliner assembly for an automotive vehicle comprises a planar center support mat adapted for mounting to a roof panel of the vehicle. A perimeter support mat extends outwardly from the outer periphery of the center support mat and is adapted for mounting to the roof panel of the vehicle. The perimeter support mat includes a main portion and an outwardly extending flap portion pivotally connected to the main portion by a living hinge. An airbag module is mounted to an interior surface of the main portion of the perimeter support mat adjacent the flap portion. The airbag module includes an inflatable airbag and an airbag canister for inflating the airbag. The flap portion is movable between a closed position covering the airbag and an open position pivoted away from the airbag providing a passageway for deployment of the airbag through the headliner assembly when inflated by the airbag canister.

Abstract: An automotive seat assembly (14) has a seat cushion assembly (13) and a seat back assembly (17). A pair of rear seat supports (28) are pivotally mounted to the rearward end (20) of the seat cushion assembly (13) for supporting a rear portion of the seat assembly (14). A pair of front seat supports (30), which each include a pair of legs (36, 38), are mounted to the forward end (18) of the seat cushion assembly (13) for supporting a front portion of the seat assembly (14). A link (40) interconnects each of the front seat supports (30) to a corresponding rear seat support (28) for moving the rear seat supports (28) between a seating position and a tumbled position. In the seating position, the front (30) and rear seat supports (28) extend downwardly from the seat cushion assembly (13). In the tumbled position, the seat cushion assembly (13) pivots upward about the front seat supports (30) and the rear seat supports (28) fold against the seat cushion assembly (13).

Abstract: A molding arrangement and method, such as slush or rotational molding, for forming a thermoplastic shell or skin product. The mold arrangement includes a hollow mold housing provided with a mold shell thereon, which together define an air chamber located within the mold housing. A plurality of air flow control devices, such as centrifugal fans, are mounted within the mold housing and direct heated air into the air chamber through discharge channels defined within the mold housing. The mold arrangement also includes an elongate air supply and heating arrangement which generates heated air within the mold housing and along substantially the entire longitudinal extent thereof to effect uniform heating of the mold shell.

Abstract: An audio speaker mounting assembly for mounting an audio speaker to interior substrate panel and sheet metal panel of an automotive vehicle includes a cover member attached to the speaker adjacent the substrate panel. The assembly further includes a retainer bracket positioned between the substrate panel and the sheet metal panel. The substrate panel includes an opening therethrough for receiving the speaker. The substrate panel is sandwiched between the cover member and the retainer bracket. The cover member includes a pair of spaced apart cover connecting structures projecting through opening in the substrate panel for locking engagement with a respective pair of retainer bracket connecting structures projecting from the retainer bracket into the opening in the substrate. An opening extends through each of the connecting structures of the cover member and is axially aligned with a corresponding through-holed in each of the connecting structures of the retainer bracket.

Abstract: A process for making a padded armrest on an interior door panel of an automotive vehicle includes the step of conforming an outer cover to a contoured surface of a mold. A blocking device is then placed against a portion of an inside surface of the outer cover and a rigid substrate if formed against the inside of the outer cover and about the blocking device providing a support structure for the outer cover. The blocking device is then removed from the outer cover and mold to form a cavity in the substrate defined by a portion of the outer cover. A resilient foam pad is inserted or formed within the cavity to provide local padded support to the outer cover.

Abstract: A fold and tumble seat support assembly (10) for removably securing a vehicle seat to a pair of front and rear strikers (12, 14) on the floor (16) of a vehicle. The seat support assembly includes a riser (20) having a pair of forward (32) and rearward (34) legs. A rear latch (36) is pivotally connected to each of the rearward legs (34) and operable by a first linkage mechanism (40) to latch and unlatch with the rear strikers (14). A front latch (64) is pivotally connected to each of the forward legs (32) and operable by a front latch handle (68) to latch and unlatch with the front strikers. A rear support leg (74) supports the rearward legs (34) of the riser above the vehicle floor (16). A foot bracket (56) is pivotally connected to each of the forward legs (32) for supporting the riser (20) above the vehicle floor (16) between both a generally horizontal use position and a forwardly pivoted tumbled position.

Abstract: A fastener assembly for attaching a trim panel to a support panel. The fastener assembly includes a clip portion having a handle end, a guide leg projecting from the handle end and a pair of locking legs projecting from the handle end and spaced parallel on opposing sides of the guide leg. The fastener assembly further includes a base portion having a bridge portion extending from a pair of base plates and defining a slot therebetween for removably receiving the guide leg therethrough, a pair of locating projections extending longitudinally from the respective pair of base plates opposite the bridge to a distal end, and a locking tab projecting from each of the locating projections toward the base plates. The base portion is adapted to retain the support panel between the locking tabs and the base plates and the clip portion is cooperable with the base portion to retain the trim panel between the base plates and the clip portion.

Abstract: A fastener assembly attaches and aligns two panels. The fastener assembly has a connector member (20), a support platform (66) and a tab (80). The connector member has a head (26), a threaded portion (32) and an annular groove (36). The support platform (66) is mounted on a first panel. The support platform (66) threadingly engages the threaded portion (32) of the connector member (20). The tab (80) is mounted on a second panel. The tab has an opening (82) for receiving the annular groove (36) of the connector member (20) in a supporting relation. Rotation of the connector member (20) moves the second panel towards and away from the first panel in a direction of draw to space the second panel relative to the first panel.