Abstract: An automotive headliner assembly includes a substrate that is configured to mount to a vehicle in a position generally covering a lower surface of a passenger compartment roof. Cavities are formed into the substrate between the upper substrate surface and the lower substrate surface to provide receptacles for electrical wiring, fiber optic cabling, EA foam and the like or to form a duct for directing air flow. Each of the cavities is integrally formed in the substrate. A foam layer is adhered to a lower surface of the substrate and the decorative cover is adhered to a lower surface of the foam layer. The headliner is constructed by first extruding molten parison into a blow mold shaped to complement the desired exterior contours of the headliner substrate to be formed. The cavities are then formed in the molten parison by inserting at least one blow pin into the parison and injecting pressurized gas.

Abstract: An apparatus for supporting a mold (100) in a press comprising a clamping plate (114, 116) comprising a wedge (172-175) and a support bracket (142-145) comprising a wedge receptacle. The wedge and the wedge receptacle act to direct the mold towards the face and vertical center f a press platen (122, 124).

Abstract: A motor vehicle (2) including a door assembly (4) configured to provide support for a canopy assembly (12) attached to the door assembly. The canopy assembly includes a canopy (18) and at least one canopy support member (20 and 22).

Abstract: A measuring gage for determining the thickness of a non-metallic material utilizes an inductive sensor positioned on one side of the material to be measured and a metallic object placed on the opposite side. The output of the sensor is used to determine the distance between the sensor and the metallic object, and hence the thickness of the material. The movement of the sensor and the metallic object can be computer controlled to map the thickness of the material along a predetermined path and produce a cross-sectional thickness profile. The output of the sensor can be used in conjunction with a computer controller responsible for adjusting the size of a score line to prepare an airbag deployment section in a vehicle trim panel.

Abstract: A method for mounting interior vehicle trim parts in which two trim parts are supported adjacent one another and in which a bead of buffer material is disposed between mating surfaces of the two trim parts. The bead is included to reduce noises such as buzzes, squeaks and rattles produced by contact and relative motion between the first and second trim parts at their mating surfaces. The bead is mechanically locked into a recess in one of the mating surfaces by forming a recess in the mating surface then applying buffer material in the recess. The buffer material is applied in such a way as to form the bead. The bead is allowed to mechanically connect to the first trim part as a result of the hardening of the buffer material within the recess.

Abstract: A temperature controlled storage container integrated into the trim member of a vehicle comprising a storage container integrated into said trim member. A thermoelectric heat pump is employed to provide temperature control to the storage container and to selectively heat or cool the container. Optionally, a duct is added that is in communication with the thermoelectric heat pump wherein the duct is also in communication with air intake resulting from motion of the vehicle and wherein the duct is also capable of venting outside of said vehicle.

Abstract: A structure for fixing a connector to a vehicle member comprising a connector, a wall provided within said vehicle including a connector fixing hole for engaging the connector, the connector comprising a first locking piece and a second locking piece and a region therebetween. The first locking piece and the second locking piece are attached to the connector and releasably engage a portion of the wall of the vehicle member at the region between the first and second locking pieces.

Abstract: An airbag deployment safety device (25) is provided comprising a first conductive path (48a) for receiving an input signal, a second conductive path (48b) for receiving an induced signal through electromagnetic coupling of the first conductive path (48a) and the second conductive path (48b), and a processor circuit (79) configured to control deployment of the airbag (25a) in response to a comparison of the induced signal to a predetermined path.

Abstract: A front structure for a motor vehicle comprising a front support connected to a vehicle frame member at a first connection location and to an engine support structure at a second connection location. Upon impact of the front structure of the motor vehicle with another object, the front support transfers energy from the impact to the first connection location, thereby reducing energy transferred to the support members.

Abstract: An apparatus for slush molding a thin shell having an outer layer and an inner layer. The apparatus includes two tubs alternately movable to a cast position for dispensing their respective material contents into a mold cavity. According to another embodiment of the invention, the apparatus includes a diverter valve configured to alternately open a passage from each of two tubs to the mold cavity to selectively dispense charge materials from the respective tubs into the mold cavity. In addition, a method is provided for forming a thin shell having an outer layer and an inner layer. A first polymer material is cast and allowed to melt on a heated mold surface to form an outer layer. A second polymer material is then cast and allowed to melt and form an inner layer on the inner surface of the outer layer. The shell is then removed from the mold.

Abstract: A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.

Abstract: An air bag cover assembly is provided comprising a retainer panel having an aperture during the deployment of an inflatable air bag for the airbag to pass through. The aperture has a cross-sectional area during air bag inflation greater than the cross-sectional area of the aperture when the air bag is deflated after being inflated. A method of providing an air bag deployment aperture for an air bag cover assembly is also provided. The method comprises providing a retainer panel, forming an aperture in the retainer panel for the deployment of an inflating air bag from an air bag module, increasing the cross-sectional area of the aperture during inflation of the air bag, and decreasing the cross-sectional area of the aperture after the air bag has at least partially passed through the aperture.

Abstract: The present invention relates to an apparatus and method of perforating the cover layer or soft skin of an automotive trim panel such as an instrument panel with a laser to allow light to bleed through the perforations. The light source would preferably be a low heat generating or “cool” type source such as an LED. The light source would be attached to a suitable substrate or incorporated in to a flexible printed circuit and coupled to the vehicle electrical system. This method would enable full switch integration to a trim panel and provide a seamless styling opportunity regarding the electrical controls. This method would help reduce cost and weight, improve quality, and promote new seamless styling theme.

Abstract: A plastic particle is formed of a plastic material having at least one integral protruding ring disposed on its outer surface. The ring may be continuous or intermittent around a perimeter of the plastic particle. Preferably, the particles have an outer diameter in the range of 0.007 inches to 0.040 inches.

Abstract: A method for forming a design in a panel includes providing an outer panel layer on an inner panel layer to form a single composite panel including two layers. The design is then formed into the panel by forming voids in the outer layer. The voids are formed by exposing predetermined regions of the outer layer to a laser beam that burns, vaporizes or otherwise removes portions of the outer layer in each exposed region. The voids create the design by exposing the inner panel layer.

Abstract: A front structure for a motor vehicle comprising a front support connected to a vehicle frame member at a first connection location and to an engine support structure at a second connection location. Upon impact of the front structure of the motor vehicle with another object, the front support transfers energy from the impact to the first connection location, thereby reducing energy transferred to the support members.

Abstract: An inflatable restraint apparatus for an automotive vehicle includes an air bag deployment door formed in a trim panel. The air bag deployment door outer surface has an area of 5 in2 to 35 in2, and at least a portion of the perimeter comprises a frangible marginal edge. The frangible marginal edge includes a frangible length, and at least 20% of the frangible length is non-linear. The apparatus also includes an air bag dispenser containing an air bag a volume of at least 90 liters. The air bag dispenser includes an elongated container having an air bag receptacle containing an air bag and an inflator receptacle containing an inflator.

Abstract: The present invention relates to an apparatus/method for making a joint line in a plastic article comprising the steps of providing a mold having a mold surface, providing a gasket in the mold wherein the gasket defines first and second mold spaces, and molding a layer of a plastic material within one of the mold first and second mold spaces. In addition, during molding, the gasket is laterally moved relative to the mold surface in a direction towards that mold space containing the plastic material to therein form a distinct joint line.

Abstract: An inflatable restraint deployment system includes a simplified hold-down assembly for fastening an air bag door in a tamper-proof closed position. The deployment system includes an air bag door pivotally supported adjacent an air bag deployment opening in an automobile dashboard and two fasteners that releasably secure the door in a closed position over the air bag deployment opening. The fasteners each include an elongated shaft portion that either extends integrally upward from an air bag canister flange or integrally downward from an air bag door substrate. The fasteners are aligned in the direction of door movement. Each fastener shaft portion extends through one of a pair of fastener holes formed either in the air bag door substrate or in the canister flange. A fastener flange extends outward from around the shaft portion of each fastener and engages a rim that defines one of the fastener holes.

Abstract: A centrifugal impeller blade is disclosed that comprises a leading edge, a trailing edge, a front surface and a rear surface. At least one of the front surface or a rear surface is at least partially defined by a radius extending from the leading edge to the trailing edge. A centrifugal impeller housing is also disclosed having one or more outlets.